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Brake Line repair help needed
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Posted by Sondeen [Email] (#796) [Profile/Gallery] (more from Sondeen) on Sat, 23 Jul 2022 23:13:45 Share Post by Email
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These questions relate to my 2001 9-3, but they are general enough that I thought they would apply across several models and are general in nature, so I am posting here. It is a long post, to skip ahead to my questions, scroll down to the ******.

One of my rear brake lines sprung a leak, at a small spot that rusted where it runs under the car about at the B pillar. The leak occurred on the way home from a short trip and I was able to get the car into my driveway but the master cylinder reservoir was basically empty when I got it home.

I was planning to replace the rear pads/rotors/calipers this summer anyway and figured now was the time to fix everything.

Choosing to tackle the rear brakes first, I gained a second problem in that the hard line going to the right rear caliper was seized into the caliper. I got the line disconnected at the flex hose and took it out with the caliper. Even after soaking the fitting liquid wrench, nothing would loosen the flare nut from the caliper. The fitting wrench ended up rounding over the hex. Vise grips were useless too and only made it worse. I have flared and bent lines before for other cars decades ago with borrowed tools, so I am confident I can make a new line once I get my own tools and parts.

I went to my local NAPA and laid out my problems. The manager said they did not carry metric brake line components, only SAE. For the the rusted line, he suggested I try a single 3/16 DOT approved compression fitting or two of these with a short length of new line in between, but he was not certain they would work with my metric 4.75mm lines.

**** Here are my questions ****

Q1: After some research, I believe I have 4.75mm lines with DIN/ISO bubble flares. The fittings look like M1-3 10mmx1.0. Can anyone tell me if I am wrong on this?

Q2: 3/16 and 4.75mm are pretty darn close to the same (3/16 = 4.76mm), is the physical line one in the same?

Q3: Are compression fittings for brake lines a good idea? (My research on the web suggests NO, because the pressure in brake lines is too high for compression fittings.) The NAPA manager was selling me on the fact that they are "DOT approved", but maybe only for fuel lines?

Q4: Any recommendations on DIN flaring tools? I am looking at the Cal-van model 154.

Q5: Any recommendations on bending tools? I am looking at an Eastwood 49074 Brake Forming Tool.

Q6: Anyone aware of a source that will fabricate a Saab line for me? It might be worth the time savings and avoiding cost of some tools.

Thank you.




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