Front brake hose, mashed connection to metal line

[SteveSarre]

Hi all

The first time I replaced the front brake hoses on a 1998 V70, I didn't fully understand how the junction between the flexible hose and the metal fixed line came apart, so I ended up chewing up the nut on the metal line. You cannot just replace the nut because the metal line has a flared end. But it went back together well enough that I lived with it.

Today on another 1998 V70 I have just fitted 302 front disks and carriers, and I replaced the front hoses (302 require slightly longer hoses than standard).
I used heat on the metal nut at the junction, and one side came apart fine. On the other side I think someone had been there before me, and the nut has a split and will not reseal.

So how do I replace that nut? Replace the whole metal line, or just cut the end off, refit a new nut and reflare the metal hose? I have not done brake hose flaring before. Or take it to a brake shop? If I know how to do it myself, I will probably go back and fix the first car. I can buy a DIY flaring kit on ebay. Any recommendations?

I also replaced all four bleeder screws while I was at it. Got these from ebay for £4.99 for the set

https://www.ebay.co.uk/itm/VOLVO-V70...C/262170310691

I am not driving it yet, but my brake warning light is now permanently on. I am hoping that that will go away when I bleed the whole system properly (after fixing that junction).

Thanks
Steve

[DunkinBiskits]

you got it mate.

either cut it off, replace nut and reflare or
find a complete used line removed from the ABS pump assembly.

I hate flaring brake lines, but even I didnt struggle too much when i reflared my rear lines due to seized brass nuts.

My kit isnt fancy AT all btw, an £18.99 kit off eBay made by Draper. A worthy addition to any garage/workshop

[cheshired5]

I had a similar problem last year.
Luckily, an old school local car parts shop made me up a new section of rigid line including flares and screw fittings for £10.
I say rigid but the replacement was copper and fairly straight so just needed gentle bending to the original profile of the old line.

[doingitsideways]

I'm with Dunc, a flaring kit is worth every penny.
Mine's paid for itself probably 50 times over through the years. (I've somehow become the go-to for busted brake lines for friends, friends of friends, their cats... Not that I ever get paid for it lol)

Only thing I'd suggest is practice on a piece of scrap is probably best for the original lines, as they're much less pliable than copper, so tend to split if you don't get them bang on.

[SteveSarre]

Hi all,

Thanks for the input. Tomorrow I'll trace the line back to the ABS unit and think about it.

Steve

[NI_Volvo_Nut]

Remove the metal pipe, measure it using string or rope, go to a local motor factors and get a new one made.

[SteveSarre]

OK, I am back on the road.

I watched quite a few Youtube videos.
This is a good one which walks you through flaring both with a cheap tool and with a more expensive tool, with pitfalls to watch for
https://www.youtube.com/watch?v=iUDyEu_NYK8

Ended up taking the original line out (from right front wheel wheel across the firewall to the ABS unit). Bit fiddly down in the corner below the master cylinder. Had to remove the scuttle drain tube (it is cabletied to another drain tube possibly from the fuse box area). Initially tried to remove the bracket which supports 2 a/c hoses, to make more space but I didn't succeed and anyway it was not necessary. The line comes out in one piece without bending, but you have to twist and turn to get it around obstacles.

Scavenged a couple of matching 14mm hex fittings from another ABS unit (on a 1998 the front lines at the ABS have a different fitting than the rear lines), and hammered one of the tubes flat to seal it, then fitted it in the ABS unit to stop it dripping when I removed the original line.

Wedged the brake pedal down with a stick (and disconnected the battery so the brake lights don't run the battery down). Confirmed that when I took my temporary plug out of the ABS unit, no brake fluid drips out.

It was quite quick to remove the old line, and to refit the new line. What took time was the hesitation and head-scratching when peering down into the rear corner of the engine bay under the fuse box.

Took the old line to a local garage together with the two spare ABS unit fittings and asked him to make two lines up (each with a new 11mm male that screws into the brake hose).
Got back with one new line this afternoon, will collect the other new line and the old line tomorrow.

Fitted the new line and bled the brakes, checked for leaks.

The garage made the new lines with copper which wasn't bent perfectly to match the old line, but copper is so soft that you can tweak it as you fit it.

Bought one of these which will be useful one day
http://www.ebay.co.uk/itm/US-PRO-Bra...8/152534805048

Since I will get the original line back in one piece, I can measure it and maybe try to replicate it myself one day. Or if I am feeling lucky I may cut the flare off, replace the 11mm male fitting that was mashed and reflare. Then I will have another spare! Or can measure the length and buy a ready-flared steel line which I would then carefully bend to shape.

Steve

PS The Volvo part number for this line is 9157972, but it is no longer available.