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Old 05-13-2010, 04:38 PM
snatiep snatiep is offline
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Exclamation Busted break line!

Hello Everyone, I hope I posted this in the right section?

The main brake line that runs down the drivers side frame rail has finally rusted through and broke on my 1996 ford ranger, 2 wheel drive.

Is this a difficult thing to replace?

Do I disconnect the broken line from both ends, pull it out, bend a new piece to match the broken one, slide it between the gas tank and rail, and re connect to both ends?

Or should I go to a salvage yard and pull one off another Ranger?

Any help or comments will be greatly appreciated!

Thanks,
Nate
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1996 Ford Ranger
2.3L engine
5 speed manual transmission

Last edited by snatiep; 05-13-2010 at 04:43 PM.
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  #2  
Old 05-13-2010, 05:31 PM
TheStig TheStig is offline
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Default Re: Busted break line!

the best thing to do would be to replace it from end to end

you could just splice in a patch.....cut and flare new ends and just bolt in a new section (i know o'reillys sells sections from 8-60" with fittings already attached)

whatever you do DO NOT use compression fittings. they are illegal in most states

its up to you and how much work you want to put into it and how bad the rest of the line is.
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1996 XLT 2.3T "White Lightning" 5/7 dropped, Turbo street toy
2006 FX4 Off Road, DD, work in progress
1985 XLT 2.8L 4x4 "The Black Pearl" (retired but still around)
1987 XL 2.3L 2wd R.I.P.
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  #3  
Old 05-13-2010, 05:33 PM
DieHard4rd DieHard4rd is offline
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Default Re: Busted break line!

Its not hard to bend new tubing from the parts store.& they dont cost much. I wouldnt waste your time with junkyard brake lines..
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Old 05-13-2010, 06:31 PM
snatiep snatiep is offline
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Default Re: Busted break line!

Thanks for the quick responses! I greatly appreciate them!

I suppose the first thing I'll do is remove the rusted brake line from the frame rail. (I hope it comes out easy!)

My local auto parts store has a 6' chunk of steel tubing for $6. I'll buy a bender and borrow a flaring set.

Then just bend the new brake line to match the rusted one, cut off the extra, flare, and install.

I think I can do it. The toughest part will be removing and trying to wind the new brake line in and around the fuel tank and frame rail.

What size is that long fuel line?

Thanks again for your generous help and tips!
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1996 Ford Ranger
2.3L engine
5 speed manual transmission

Last edited by snatiep; 05-13-2010 at 06:47 PM.
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  #5  
Old 05-13-2010, 07:14 PM
TheStig TheStig is offline
My truck snorts.
 
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Default Re: Busted break line!

brake line is 3/16 double flare
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1996 XLT 2.3T "White Lightning" 5/7 dropped, Turbo street toy
2006 FX4 Off Road, DD, work in progress
1985 XLT 2.8L 4x4 "The Black Pearl" (retired but still around)
1987 XL 2.3L 2wd R.I.P.
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I love me some Stig
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  #6  
Old 05-14-2010, 09:46 AM
snatiep snatiep is offline
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Default Re: Busted break line!

Well I unscrewed the broken brake line from both ends and I cannot remove it from the frame rail. I tugged and tugged but it wont come out. I'm thinking I have to remove the fuel tank to get it out. That would also make it easier to install the new line.

Can I replace the brake line without removing the fuel tank?

Or should I remove the bed of the truck to access the brake line?

Thanks for the help!
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1996 Ford Ranger
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5 speed manual transmission

Last edited by snatiep; 05-14-2010 at 10:34 AM.
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  #7  
Old 05-15-2010, 06:22 AM
snatiep snatiep is offline
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Default Re: Busted break line!

Well I talked to a bus mechanic at work yesterday afternoon and he said to forget about removing the gas tank or the truck box and just route the new line safely around the gas tank in a new path and protect it from rubbing on anything, zip tie it.

I have a friend who works at Checker auto and he brought me 2 60" pieces of metal brake line that can be bent with your hands. Man is that stuff slick!

Now I just have to get a friend to come over today and help me bleed them!
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