Need to replace brake line from antilock to rear brakes

[Lee_H]

Well, my brake adventure with pictures. Removed the main line along the driver side frame rail. The rust gave out in a hurry so disassembly was not a problem. A comparison to the nice shiny replacement lines.

 

[Lee_H]

The new line is in three pieces for shipping and ease of installation. Tried to install with tire left on, not really working. Did tape up the union end to keep dirt out.

 

[Lee_H]

Decided to jack up the driver's side and chock the passenger's side. My little floor jack could not go high enough, used truck's jack and jack stands instead.

 

[Lee_H]

This is the view of the "supply" brake line going in, not too bad to assemble.

 

[Lee_H]

Now the back half.

 

[Lee_H]

Since I knew I was most likely unable to fasten the line going to the passenger's side via over the fuel tank. So I did something to help the line not be damaged fishing it through. Pictures show new tank straps and line (in two sections) before and after.

 

[Lee_H]

Now I needed to be under the truck. Safety First! I borrowed a bigger floor jack and rested some of the weight on the car ramps with a 2 by 8 acting as a spacer. The rest of the weight was on jack stands. I also had a old scissor jack with a sheet of plywood supporting the fuel tank to change out the straps. I did the straps first, then the brake line.

 

[Lee_H]

The front strap was not too bad to twist out. Replacement strap was not bent the same. Some some adjusting was needed using two pipe wrenches. Picture shows the "before" lol.

 

[Lee_H]

Back strap is locked into the frame by the drive shaft and the fuel tank itself. Tried to break the stap off but no luck with that. Ended up saying some prayers and got my HF sawzall out with a short blade and used the drive shaft as a guide. The fuel tank and Shaft ended up damage free in the end. That was the out. Same problem with the new part as well. Got my die grinder out and modified the strap to fit.
NOTE TO MANUFACTURES! If you extend the folded section down and punch the "smile face" in both strap sections you will be a mechanic's hero since the drive shaft can remain attached. As it is, I accept it is not as strong as it was unmodified but much stronger than the rusted part it replaced. Maybe not the best solution but it is what I ended up with.

 

[Lee_H]

I maneuvered the cross over brake line after cutting the old line from the flexible frame to wheel line connections. I could not remove the old line without damaging the fuel tank so it remain in the truck. I needed to stretch the driver side line to get to the connection point. This left the passenger side with too much line. I wish the connection point was over to the passenger side more. I could have checked for leaks a lot easier. NOTE: This post was flagged for an unknown reason.