Replacing a brake hardline on a ZJ..

[OverlandZJ]

I assume this is very similar to an ABS setup on an XJ so i'm hoping you guys can help.

Working on a 95 ZJ that had a hardline rupture at the rear axle softline. Picked up 3/16 hardline but also needed a 6" piece with a bubble flare at the ABS pump, cut other end and redid it to a double flare.

The problem i'm having is getting the union at the end of this short section and the following 10' section to not leak. I'v cut and reflared it a few times.. one side is leaking slightly. And i havent attempted to bleed the system yet.

Is there a union for double flare AND bubble flare? I'm wondering if i have a bubble union. It tapers in towards center of union.. whereas i would suspect a double should have a taper towards outside?

 

[joe_peters]

Which are you working with:

http://forums.pelicanparts.com/uploads12/double+vs+bubble+flare1201238131.jpg

Flaring: http://www.waterbugdesign.com/pics/keypad/DoubleFlareDiag.jpg

 

[OverlandZJ]

Both Joe..

The hardline at the ABS pump is a bubble flare, rear softline is a double flare.

I bought a short section of 3/16" line that had a preformed bubble flare on both ends, attached one end to ABS pump and cut the other end. Reflared to a double flare and had issues with leakage.

Finally i ended up cutting the doubles off at both sides of the union and eliminated the second step in the double flare and reassembled, torqued it down tight and got it leakfree.

I had to use a shorter section at ABS pump because i couldnt get the 11' section fed all the way up from rear axle to ABS pump... to many bends and stuff to work around.

I just finished up the job. Gonna have it brought back in a week to recheck things and another quick bleed.

 

[joe_peters]

Ok.

If I understand you ended up with a single flare at the union. If this is correct, not a good idea, stopping and safety wise.

The most common cause of a leaking double-flare is an in-expensive flaring tool. You can sometimes overcome that by using some crocus cloth to clean up the outside of the steel line, keeping crap out of the line and rinsing with brake cleaner before crimping.

 

[OverlandZJ]

Appreciate your input Joe. I bought a new flaring tool at NAPA and they hit me for 70 on an imported tool. Dunno...

I did the second step but did so lightly. In the end i took the whole 10' line out and tightened down the union better than i was able to along the unirail under the hood. That was enough to stop the slight leak. A few days driving and keeping an eye on it has me somewhat confident it's fine. I'll keep my eye on it.

Thanks..

 

[joe_peters]

Glad you got it.

Good luck.