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5-9
1977 PONTIAC SERVICE MANUAL
WARNING:
NEVER
USE
COPPER
TUBING BECAUSE COPPER IS SUBJECT
TO
FATIGUE
CRACKING
AND
CORROSION WHICH COULD RESULT IN
BRAKE FAILURE.
Fig.
5-6
Bleeding Wheel Cylinder
BRAKE HOSES
The flexible hydraulic brake hose, which transmits
hydraulic pressure from the steel brake line on the body to
the rear axle and to the calipers, should be inspected at least
twice a year when the car is on a lift for lubrication. The brake
hose assembly should be checked for road hazard damage,
for cracks and chafing of the outer cover, and for leaks and
blisters. A light and mirror may be needed for an adequate
inspection. If any of the above conditions are observed on the
brake hose it will be necessary to replace it.
FRONT BRAKE HOSE
Removal
1. Clean dirt and foreign material from both hose and
fittings.
2. Disconnect brake pipe from hose fitting using a back-
up wrench on fitting. Be careful not to bend frame bracket
or brake pipe. It may be necessary to soak the connections
with penetrating oil. See Figures 5-7, 5-10, 5-13 and 5-15.
3. Remove "U" clip from female fitting at bracket and
remove hose from bracket.
4. Remove bolt from caliper end of hose. Remove hose
from caliper and discard the two copper gaskets on either side
of fitting block.
Installation
1. Use new copper gaskets on both sides of fitting block;
wet bolt threads with brake fluid. With fitting orientation
flange engaged with the caliper orientation ledge, fasten hose
to caliper and torque to specifications.
2. With weight of car on suspension, pass female fitting
through frame bracket or crossmember. Fitting fits the
bracket in only one position. With least amount of twist in
hose install fitting in this position. There should be no kinks
in hose.
3. Install "U" clip to female fitting at frame bracket.
4. Attach brake pipe to hose fitting using a backup
wrench on fitting. Torque to specification.
5. Inspect to see that hose doesn't make contact with any
part of suspension. Check in extreme right hand and extreme
left hand turn conditions. If hose makes any contact, remove
and correct.
6. Bleed brake system.
1. Procure the recommended tubing and steel fitting nuts
of the correct size (outside diameter of tubing is used to
specify size).
2. Cut tubing to length. Correct length may be
determined by measuring old pipe using a cord and adding
1/8" for each double flare.
b
3. Double flare tubing ends using a suitable flaring tool
such as J 23530. Follow instructions included in tool set.
Make sure fittings are installed before starting second
flare.
REAR BRAKE HOSE
WARNING: DOUBLE FLARING TOOL
MUST BE USED AS SINGLE FLARING
TOOLS CANNOT PRODUCE A FLARE
STRONG
ENOUGH
TO
HOLD
THE
NECESSARY PRESSURE.
4. Bend pipe assembly to match old pipe using a tubing
bender. Clearance of .750 must be maintained to all moving
or vibrating parts.
5. Route pipes as shown in Figures 5-7 through 5- 18
Removal
1. Remove all three brake pipes from hose; two at
junction block and, with the use of a back-up wrench, one
on the female fitting at bracket. Be careful not to bend bracket
or pipes; use penetrating oil if necessary. See Figures 5-9,
5-12, 5-15 and 5-18.
2. Remove "U" clip and take female fitting out of
bracket.
3. Observe position at which junction block is mounted
to the axle. When installing new hose, be sure this junction
block is in the same position.
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