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Vacuum Hose Repair - Mini-Tube

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S) CHART

G03910367
 Vacuum Pump Kit 416-D002 (D95L-7559-A) or equivalent
  1. Measure the length of the damaged area of the mini-tube vacuum hose.
  2. Cut a piece of standard 1/8-inch inner diameter vacuum hose approximately 25 mm (1 inch) longer than the damaged area of the mini-tube vacuum hose.
  3. Cut off the mini-tube vacuum hose on each side of the damaged area.
    4. WARNING: Read the warning information on the product label to prevent possible personal injury.
  4. Dip the mini-tube hose ends in commercially available paint thinner containing methyl ethyl ketone (MEK). This solvent will seal the mini-tube in the vacuum hose.
  5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 inch) into the ends of the standard 1/8-inch repair vacuum hose section.
    Fig 1: Identifying Insert Dimension Of Mini-Tube Vacuum Hose
    G03879312Courtesy of FORD MOTOR CO.
  6. Shake the repair joint after assembly to make sure the solvent is dispersed and the vacuum line is not plugged.
  7. Test the system for a vacuum leak in the repair area.
    • Use the Vacuum Pump or equivalent.
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