New brake line flares won't seal at ABS Pump ports

[rwc265]

Hi all. Had an issue with my front passenger brake line blowing out on one of the angled portions after the braided hose part, right where there's a rubber insulating elbow that apparently got water trapped under it. Had enough brake pressure to get home, had it towed to my shop so I could work on it. Long story short I popped the line in question off the ABS pump, flared up a new end on my NiCopp line, and put the original fitting back on and sent it home. However even with no pressure on it and the end of the line just open, I can't get the flare to seal, it keeps leaking from the top of the nut. Tried the Maddox flare tool from HF instead of the cheap performance tool one, tried a new nut, I even gave up and went back to the store and got a factory premade line for double flare, M10x1 thread and it still leaks out the top.

I'm guessing something had to happen to the ABS port, wondering if maybe I overtightened it? I sent the nut until it didn't turn anymore, but didn't force it back that point either. Maybe just a hair past snug was it? Hoping someone can clarify that. But what I also need to know ASAP at this point, are the ABS pumps themselves different between years? The part number I got off Alldata looks like it's specific to my year but I don't know if that's because of the computer half, pump half, or both. The HCU and electronic assembly for my year is over a grand, but if I can buy any old 3rd gen ABS pump off eBay and just swap the computer, I'll save a lot of money.

Also, the fittings for the ABS pump ARE M10x1, right? That's what I read, and that's what I bought at the store and it went in easily by hand

 

[rwc265]

I'm not 100% sure it'll work but I have the pump and module assembly from an 08 coming in from eBay for $50. I'm pretty sure the module won't work but as far as I can tell, the pumps themselves are all the same for like 07-09 at least.

 

[rwc265]

Long story short, 08 ABS pump works with an 09 module. I'd assume any pump from a 3rd gen expedition where the ports/threads match and has 2C405 as a base part number is probably the same, seems the only difference between the assemblies they sell for the different years is the module itself. I put my original module on the eBay pump, but even the module that came with it I'd imagine could've been flashed with my as-built ABS data since I compared the pinout between 08 and 09 and it was an exact match. Anyway, triggered the ABS bleed today with my scan tool and bled em up normally, finally got no leaks and everything's back to 100%.

 

[sz0077]

I had an 06 XLT that the line from the ABS back to the fitting to the rear end rusted out. I bought some premade lines (I had to use two lines)from AutoZone, I couldn’t get it tight enough and it was leaking like crazy, so in a last ditch effort, I ended up tightening the line into the ABS with vice grips. It obviously messed up the hex fitting on the line, but it tightened it enough to not leak. Not the right way to do it, but it worked for an emergency fix