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2nd Gen Non-Engine/Transmission Brake leak seeking advice

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Engine/Transmission (1998.5 - 2002) screw on Fuel Filter base

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I have discovered a major brake fluid leak between my fuel tank and the frame on the driver's side. I know the Green Monster is nearing greener pastures but I don't want to give up yet... .

  • What is the best way to attack that location (with a rusty vehicle)?
  • Is it time to pull the bed and survey the corrosion damage underneath?
  • Should I try to just pull the tank to gain access to the leak?
  • Is there another way to approach this problem?



After replacing my Clutch Slave with the fine South Bend system from Geno's, I am sad to discover a big brake line failure. Apparently when I did the panic stop to prevent slamming into my trailer when the clutch failed, I must have popped a weak brake line.



I imagine I will find a nice pile of road dirt and corrosion in the frame pocket near the tank.



Bummer :{
 
David, This is not a big deal, just measure the line from the rear-end to where it ends at the front-end. You can buy random lingths and couplings to make up what you need making it just a tad longer. Disconnect old line and bend the ends out of the way. Then assemble new sections w/couplings (very tight), tape both ends shut till ready to connect to front and rear to keep dirt out and slide it down the frame rail and behind the tank. You will have to make a couple of bends at the rear, just measure. Just leave the old line in there where you can't get to it.



Oh yea you will have to bleed thr rear breaks. Hope this helps.
 
hi; and dont forget to get it held ,sufficiently that theres no vibration and chafing driving down the road or you will be doing it again !i recomend to pull the tank next time its low around 5 to 10 gallons ,left so you can handle the weight on your back and clean the chassis out and make sure the line is in the chassis clips ! safety first !
 
Thank you for the support.



Kind of frustrating to fix one thing and have another surface.



I emailed the Dave Smith dealership for motivation..... It came in the way of a price I can't quite afford yet... :)



So off to the parts store for some brake lines...
 
I recently replaced all the brake lines and hoses on my 98QC. It's not as hard as I thought it would be. New hoses in three locations, a 25' coil of line, a double flare tool, and a few fittings/unions is what is needed. I had rust at most connections, replacing one line would have been a band-aid until the next rupture. I snaked my line in the frame behind the tank, I sleeved it to protect it. I'm starting to enjoy fixing up my 98, parts are cheap.
 
Pulling the tank is a sleeper job, if you are going to do the replacement, do it right and pull the tank.

If the tank is 1/2 full or better (which is usually the case when the tank needs to come out) and you don't want to try to drop it loaded, then you can use the lift pump to drain the tank into a barrel or fuel cans. Another option is to loosen the tank straps and lower the tank a bit, disconnect the fill hose and drain it with a hand pump.
 
I enjoyed the parade today and the fire works last night. Happy 4th to all.



SO, this afternoon I crawled back under the wounded beast. I have decided to follow the advice to pull the tank if I can.



I looked at the tank straps. The hardware looks rough but maybe... . The last time it was off was when I installed the ESPAR fuel line. The hardware was not rusted that time. I hope that I did not over torque the fasteners that time.



I will need to replace the line from the proportioning valve, above the axle, to somewhere forward of the fuel tank. All the brake lines look bad but the attached photo is of the line near the fuel tank. I held my blackberry above the frame and shot down in the blind. With my fingers I can pull layers and layers off the brake lines as if they are peeling apart.



A few days to do this and then I am back off to a job in the middle east for a bit.



thanks all, I will update this thread when I get it finished.
 
I replaced the rear portion of my brake line. It was not leaking yet, but had read on here about the common problem. I had my fuel tank down, while installing my Air Dog. I bought a 6 ft length of 3/16" brake line and measured forward from the flex hose to hard line connection. I cut the old line at the area of my measurement, leaving a couple of inches, until I had the new line bend and reconnected at the flex hose fitting. I installed a new nut and double flared the old line, then attached the new and old line with a coupler.
 
just had that happen to mine . I broke the line at the tee above the rear axle and in front of the tank I cut the line . pulled the line out of the hangers ( it done it's rusting in the hangers) sprayed the underside with rust killer . the next day put new line in .
 
Dave - NAPA for the correct line size, if you are lucky they may have stainless if not standard will do for the next 10 years or so. Make sure you get the fittings for the line ends. What worked for me was to disconnect the front line where it connects to the brake block on the frame, left wheel house just behind the inner plastic fender and then disconnect where it connects to the load sensing device aft of the fuel tank. Take the old piece out in one section - now leaving about 4" run wild at whatever end you decide to start - take the spool of new line (sorry forgot to mention its probably 25") and wire tie a section to the old, using a tube bender make your first bend copying the old line. Wire tie before and after the first bend and keep repeating until to get to the last bend. You'll be best sitting in the driveway or if there's enough room somewhere out of the sun you'll need about as much space as it would take to park your truck to work. My neighbors got a good laugh at me fighting two skinny snakes in my driveway back 5 years or so when I had to do mine. Anyway, once you get the new line bent up where it matches the old cut the ends - leave about 1/2" extra tube on each end for fudge factor when it comes to making up the double flares - Ah - don't forget to install the line nuts before making the double flares - bet you can guess how I'm able to offer that little reminder . . .

Oh, the old line will fish out from the front, feeding it thru the space between the engine and the front differential (if 4WD) not sure on 2WD. Then the new line will feed the opposite way. Install using the clips so it doesn't contact the frame, if it contacts the frame you can wire tie a piece of hose to prevent chafing down the road. Once the line is in the body hand thread both nuts in all the way then back out the rear nut a few turns - tighten the front one securely. Pour in the brake fluid and it should gravity flow out the rear nut you left loose - if not there's a little block under the m-cylinder (rear only abs assuming your 99 is like mine) with a rubber cap covering a little valve pop-up thing (forget what its called) have someone step on the pedal and catch the pop-up and secure it from going back into the block - a set of needle nose vice-grips with electrical tape on the tips works well so as not to mar the valve pop-up thing.

This should allow gravity flow. If not go the old fashion route you at the rear nut, someone else at the pedal (unless you have a power bleed kit) until you get fluid at the rear nut - tighten securely. Then proceed to the right rear and etc.

If you don't have a hard pedal you may have to disconnect the load sensing arm rod to the frame and place arm in the up or fully down position to get good flow/all the air out of the sensing device.

It's fun, but beats the heck out of paying someone else to do it.
 
rrl989,

Thanks for the input. How did you sleeve the line?



I used a length of poly tubing and slid it over the coated brake line, I was not sure how I would secure it so I did not want it bouncing around unprotected. It turns out the OEM line is only secured at the front of the tank, and rear on the frame, so I did secure it back down anyway. IMO, there would be no gain dropping the tank.
 
Thanks again for all the input on this one!! Joe Mc great detail in your post!

I pumped about 10 gallons out of my tank today. Easy since I have a 12v pump and had two empty cans for the tractor. The tank is now down to about 1/4 if I decide to pull it.

Today I would have replaced the line but I could not find anyone open with a flaring tool. If I can find what I need tomorrow I may dive into it tomorrow night. Unfortunately the overseas biz trip is almost upon me. Either it gets done tomorrow or the truck will have to wait a few weeks for me to return. :(
 
It's easier with the tank down - at least you can see what you're doing and get a good handle on snapping the new line into the factory mounts. Might as well go for it if the tank is already low.

Have fun.
 
Just did all the rear brake lines in the old "commuter caddy". Called one of my customers that does a lot of auto work and asked what people were using for brake lines nowadays. He said to get the Copper Nickel Alloy brake line from NAPA. Bends without kinking and double flares or bubble flares easily. It is legal and has been in use by several automakers including Volvo for some time. It will the last time that you have to frig with them. VERY EASY to work with, no tubing bender needed. Part # 641-3347 at NAPA. 25' costs about $35. 00.

I had done several complete brake line replacements using the powder coated line in hopes of holding back the calcium creeping crud up until now but it is Copper Nickel Alloy for me from now on.

Also purchased a bubble flare kit as I am tired of the extra expense of having to buy a handful of adaptors. Wish I had done it sooner as it is less labor intensive and only consists of one step instead of the two steps needed when you double flare. Much, much simpler when you are flaring a line under the vehicle.

Buy some 10mm and 12mm brake tubing nuts and off you go.

Hope this helps and only wanted to offer you a second option to consider.

Mike.
 
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Well, here we go on the 99 Dodge Brake lines (finally!!)

I am finally back home and have taken a few days off to get my rigs working while the weather is still warm. 15 days home from the start of May has been tough on the honey do list.

Yesterday was parking brake pads for the 04 CrownVic (ex-cruiser now commuter beater rig).

Today I return to the old rusty dodge and attack the brake lines.

Off to buy a flare tool, cheap bender, metric connectors and 3/16th brake line. I think I will try the NAPA copper ni alloy suggestion above and replace the entire line from front to back! Worst case I screw it up and limp it to the shop with the parking brake.

After that I have to move on to the outdoor wood boiler. Either it gets welded up or replaced by a nice ecological friendly vermont mandated $12K new outdoor wood boiler. (so saving money on the brake jobs helps in some minor way. . :) )

Thx all for the ideas and input! Time to renew my membership. . Still a good investment!!
 
David,



If you can’t find a flaring tool locally, check McMaster-Carr. Here is their on-line page for those:

McMaster-Carr



Their service is fantastic, and although they don't quote shipping on-line the charges will be more than reasonable.



Good luck,

– Loren
 
It has brakes again!!
I must confess after finding all the parts and tools for the job, my guilty conscience about being away from home so much kicked in.
I decided to spend the day with my wife and dropped the truck off to a friend with a new repair shop. Less than $125, no injuries or stress for me, and making points with my wife..... priceless.

Thanks again for the advice and support!!
 
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