Flare Brake Line - AR42.10-S-0027-01E

Model All (Light transporter) 

Fig 1: Identifying Flaring Tool (000 589 20 99 00)

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All of the individual tools required for the repair can be taken from the tool kit flanging tool kit.

Brake lines with ø 4.75 mm are flanged without peeling and making first-stage flange.

Brake lines with ø 4.95 mm and ø 5.25 mm must be peeled and a first-stage flange made.

WIS Service Media 

GB42.10-S-0000-00A (See start of document for link)

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Peel brake line 

Only perform operation steps  1 to  3 for brake lines with ø 4.95 mm or ø 5.25 mm.

1. Clamp brake line in line holding pliers (1) so that the end to be worked on protrudes approx. 50 mm (dimension x).
2. Clamp step drill bit (2) into a commercially available cordless drill/driver.

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3. Operate cordless drill/driver and press step drill bit (2) on brake line up to contact.

   In this way, the plastic coating in the flaring area is removed.

   Clean the step drill bit (2) if soiling is present. Otherwise, the entire insertion depth in the step drill bit (2) is no longer guaranteed for the next step drill procedure.

   Prepare flanging tool kit (3) 

4. Insert clamping brackets (7) assigned to brake line diameter into flanging tool kit (3).

   The clamping brackets (7) are held magnetically in their positions in the flanging tool (3).

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5. Close latch (12) in flanging tool kit (3).
6. Insert brake line with end to be worked on up to end stop on latch (12) in flanging tool kit (3).
7. Tighten tensioning screws (9) of clamping plate (8) evenly in stages .

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8. Mark position of brake line relative to clamping brackets (7) using a pen as shown (arrow A).

   This means that it is apparent if the brake line is not held correctly in the clamping brackets (7).

9. Open latch (12).

   Make first-stage flange of brake line 

   Only perform operation steps  10 to  17 for brake lines with ø 4.95 mm or ø 5.25 mm.

10. Insert punch "A" (5) into punch holder (6) and fix in place with locking clip (11) in area of hexagon.
11. Clean punch holder (6).
12. Clean punch "A" (5) in front area (arrow B).
13. Apply ATE brake cylinder paste at punch "A" (5) in front area (arrow B) and at end of brake line to be worked on.

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14. Screw punch holder (6) with punch "A" (5) into flanging tool kit (3) so that tip of punch "A" (5) lightly touches brake line.
15. Make first-stage flange of brake line by slowly screwing in punch holder (6) with specified tightening torque .
16. Remove punch holder (6) from flanging tool kit (3).
17. Remove locking clip (11) and remove punch "A" (5) from punch holder (6).

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18. Insert punch "B" (4) into punch holder (6) and fix in place with locking clip (11) in area of hexagon.
19. Clean punch holder (6).
20. Clean punch "B" (4) in front area (arrow C).
21. Apply ATE brake cylinder paste at punch "B" (4) in front area (arrow C) and at end of brake line to be worked on.

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22. Screw punch holder (6) with punch "B" (4) into flanging tool kit (3) so that tip of punch "B" (4) lightly touches brake line.
23. Make finished flange of brake line by slowly screwing in punch holder (6) with specified tightening torque.
24. Remove punch holder (6) from flanging tool kit (3).

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25. Release tensioning screws (9) evenly until brake line with clamping brackets (7) can be taken out of flanging tool kit (3).
26. Release and remove clamping brackets (7) from finished, flanged brake line.