Q: How to inspect and replace flexible brake hoses and metal brake lines?
A: About every six months, the flexible hoses that connect the steel brake lines with the front and rear brake assemblies should be inspected for cracks, chafing, leaks, blisters, and other damage. These hoses are important and vulnerable parts of the brake system, so a thorough inspection is necessary. If any of the above conditions are found, the hose should be replaced with a new one. To replace a flexible hose, start by cleaning away any dirt from the ends of the hose. Then, disconnect the hose at the frame end by holding the nut steady and loosening the other union nut. Soak the connections with penetrating oil if necessary. Once the hose is disconnected from the metal line, detach it from the frame bracket. To detach the hose from the Brake Caliper, unscrew it or remove the banjo bolt and copper crush washers. When installing the new hose, make sure all brackets are in good condition and the locknuts are tight. Check that the suspension and steering components do not make contact with the hoses. Bleed the brake system after installation. When replacing metal brake lines, use proper steel brake lines and avoid using copper lines. Prefabricated brake lines with flared ends and fittings are available, or you can obtain the recommended steel tubing and fittings to match the line being replaced. Cut the new tubing to the correct length, allowing extra for flaring the ends. Install the fitting over the cut tubing and flare the ends with an ISO flaring tool. Bend the line to the proper shape if necessary. Ensure the new line is well supported in the brackets and has proper routing. Check the Brake Master Cylinder fluid level, add fluid if necessary, and bleed the brake system before testing the brakes for any leaks.