Brake Line Issues

July 16, 2007, 11:43:59 AM

I have a 1989 Mercury Cougar LS, that my father bought new in July of 1989. This Cougar wasn’t driven much and only has approximately 40,000 original miles on it. It has sat in the driveway, mostly un-used and it has probably only been driven about 5,000 miles, over the last 10 years.
The main metal brake lines, from about the bottom of the engine compartment, to the rear brakes, are rust coated at several locations and may be deteriorating to a point that replacement may be necessary. In fact, there is a brake fluid leak in the brake line at the right rear wheel, at the metal bend, just before it enters the right rear drum brake wheel cylinder, due to rust. I positively have to replace the right rear brake line, which I already purchased, (as well as a new brake cylinder), for this wheel. So far, I have been unable to break the threaded connection where this right rear brake line connects to the main metal brake line on the wheel well. I tried penetrating oil and WD40 but, nothing worked. The outer edges of the nut is becomming rounded and the flare nut wrench no longer fits tightly. Since I might have to replace the entire brake line from the brake block attached to the Master Cylinder, to both rear wheels, this connection that I can‘t break doesn‘t seem like a problem anymore,…I‘ll simply replace it. After looking at the brake lines and seeing where they were routed, (from the brake block under the hood to the rear wheels), it appears much more do-able, than I first thought possible. A few hours on the internet, uncovered several places that sell replacement brake lines. I suppose my local Mercury dealer could sell me the exact OEM brake line but, I’m not sure that I could install it as one piece, if that’s how it is sold. I was hoping that someone that is experienced with this problem could offer some advice, technical pointers or tips. Is there a better way to break the connection that I can't break? If the rest of the brake line isn't leaking, should I just let it be? If I decide to replace the entire brake line, is the brake line a standard size,…should I insist on a particular type of line or manufacturer or material over another,…should I just buy a coil of brake line and flare the ends myself,…can I purchase a correct length with correctly flared ends or do I need a special flaring tool to make my own ends,…etc. Thank you.

Brake Line Issues

Reply #1 – July 16, 2007, 04:34:14 PM

as far as gettin that connection apart. you already have the new line, cut the old one off and try a 6pt socket on the flare nut.

Brake Line Issues

Reply #2 – July 16, 2007, 06:58:43 PM

As long as it no longer matters what the nut looks like, I've found real tight vice grips do a great job on biting into the metal and allowing the thing to loosen.

Regarding the brake lines, its probably best to buy a long coil (Summit has them, along with new flare nuts) and a flare tool ( I like Rigid brand the best), and a bender. Then practice a little with both tools before putting the run into the car.

I first tried removing the original line and bend the new line to try to match it before putting it into the car, but it didn't work too well- the 3D nature had more dimensions than my mind. So I found it better just putting it into the car while doing the bends.

The stainless steel tube is nice, but I found it really hard to flare, so I've gone with Summit SUM-220136, standard steel line.

I'd be real surprised if you could find prebent tube for your car at a dealer.

Brake Line Issues

Reply #3 – July 16, 2007, 07:55:05 PM

Practice doing the double flare on the extra brakeline before you tackle your new pieces.

Brake Line Issues

Reply #4 – July 16, 2007, 10:16:49 PM

Thank you for the information! I'll give these ideas a try!

Brake Line Issue Fixed

Reply #5 – July 17, 2007, 07:49:35 PM

Well, I was able to remove the bad right rear brake line and install the new line. With the idea of, "If It Isn't Broken, Leave It Alone,"...I've decided not to touch the rest of the brake lines,...at least for the immediate time being. My Cougar is once again roadworthy.
I wish to thank GUMBY, BONDOCOUGAR and PROTOTYPE SERVICES, for their prompt and great advice. I'm glad I found this web site!