Tools Required
J 45405 Brake Pipe Flaring
Kit
Caution: Refer to Brake Fluid Irritant Caution in the Preface section.
Caution: Always use double walled steel brake pipe when replacing brake pipes.
The use of any other pipe is not recommended and may cause brake system failure.
Carefully route and retain replacement brake pipes. Always use the correct
fasteners and the original location for replacement brake pipes. Failure to
properly route and retain brake pipes may cause damage to the brake pipes
and cause brake system failure.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.
Notice: There is a first design and second design of brake pipe flare for the hydraulic
brake pipes and system components used on this vehicle. Do NOT mis-match flare types.
If the flare types are mis-matched, damage to the pipes and/or components, and/or
a brake fluid leak may occur.
• | First design, ISO flare (1) |
• | Second design, double inverted flare (2) |
Important: When servicing brake pipes, note the following:
• | If sectioning brake pipe, use replacement pipe of the same type and outside
diameter. |
• | Use fittings of the appropriate size and type. |
• | Only create flares of the same type or design as originally equipped on
the vehicle. |
- Inspect the section of brake pipe to be
repaired or replaced.
- Release the brake pipe to be replaced from the retainers, as required.
- Select an appropriate location to section the brake pipe, if necessary.
• | Allow adequate clearance in order to maneuver the J 45405
. |
• | Avoid sectioning the brake pipe at bends or mounting points. |
- Using a string or wire, measure the length of the pipe to be replaced
including all pipe bends.
- Add to the measurement taken the appropriate additional length required
for each flare to be created.
Specification
6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter
pipe
Important: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle
to the pipe length.
- Using the pipe cutter included in the J 45405
, carefully cut the brake pipe squarely to the measured length.
- Remove the sectioned brake pipe from the vehicle.
- Select the appropriate size of brake pipe and tube nuts, as necessary.
The brake pipe outside diameter determines brake pipe size.
- Strip the nylon coating from the brake pipe
ends to be flared, if necessary.
• | Select the appropriate blade on the coating stripping tool included in
the J 45405
, by unthreading the
blade block from the stripping tool and installing the block with the desired blade
facing the tool rollers. |
Specification
6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter
pipe
• | Insert the brake pipe end to be flared into the stripping tool to the
depth of the ledge on the tool rollers. |
• | While holding the brake pipe firmly against the stripping tool roller
ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe
coated surface. |
| Important: Do not gouge the metal surface of the brake pipe.
|
• | Rotate the stripping tool in a clockwise direction, ensuring that the
brake pipe end remains against the tool roller ledges. |
• | After each successive revolution of the stripping tool, carefully rotate
the thumbwheel of the tool clockwise, in order to continue stripping the coating
from the brake pipe until the metal pipe surface is exposed. |
• | Loosen the thumbwheel of the tool and remove the brake pipe. |
| Important: Ensure that all loose remnants of the nylon coating have been removed from the
brake pipe.
|
• | Inspect the stripped end of the brake pipe to ensure that the proper amount
of coating has been removed. |
Specification
6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter
pipe
- Chamfer the inside and outside diameter
of the pipe with the de-burring tool included in the J 45405
.
- Install the tube nuts on the brake pipe, noting their orientation.
- Clean the brake pipe and the J 45405
of lubricant, contaminants, and debris.
- Loosen the die clamping screw of the J 45405
.
- Select the corresponding die set and install the die halves into the die
cage with the full, flat face of one die facing the clamping screw, and the counterbores
of both dies facing the forming ram.
- Place the flat face of an unused die (1)
against the die halves in the clamping cage and hold firmly against the counterbored
face of the dies.
- Insert the prepared end of the pipe to be flared through the back of the
dies until the pipe is seated against the flat surface of the unused die (1).
- Remove the unused die (1).
- Ensure that the rear of both dies are seated firmly against the enclosed
end of the die cage.
- Firmly hand tighten the clamping screw (2) against the dies.
- Select the appropriate forming mandrel and
place into the forming ram.
- Rotate the hydraulic fluid control valve clockwise to the closed position.
- Rotate the body of the J 45405
until it bottoms against the die cage.
- While guiding the forming mandrel into the
exposed end of pipe to be flared, operate the lever of the J 45405
until the forming mandrel bottoms against the clamping dies.
- Rotate the hydraulic fluid control valve counterclockwise to the open
position to allow the hydraulic forming ram to retract.
- For ISO pipe flares:
• | Loosen the die clamping screw and remove the dies and pipe. |
• | If necessary, lightly tap the dies until the die halves separate. |
• | Inspect the brake pipe flare for correct shape and diameter (a). |
Specification
7.10 mm (0.279 in) +/- 0.18 mm (0.007 in)
flare diameter for 4.76 mm (3/16 in) diameter pipe
- For double inverted pipe flares:
• | Insert the finishing cone into the forming ram. |
• | Rotate the hydraulic fluid control valve clockwise to the closed position. |
• | Rotate the body of the J 45405
until it bottoms against the die cage. |
• | While guiding the finishing cone into the exposed end of pipe to be flared,
operate the lever of the J 45405
until the finishing cone bottoms against the dies. |
• | Rotate the hydraulic fluid control valve counterclockwise to the open
position to allow the hydraulic forming ram to retract. |
• | Loosen the die clamping screw and remove the dies and pipe. |
• | If necessary, lightly tap the dies until the die halves separate. |
- Inspect the brake pipe flare for correct
shape and diameter (a).
Specification
6.92 mm (0.272 in) +/- 0.18 mm (0.007 in)
flare diameter for 4.76 mm (3/16 in) diameter pipe
Important: When installing the pipe, maintain a clearance of 19 mm (3/4 in)
from all moving or vibrating components.
- If necessary, using the removed section of pipe as a template, shape the new
pipe with a suitable brake pipe bending tool.
- Install the pipe to the vehicle with the appropriate brake pipe unions,
as required.
- If previously released, secure the brake pipe to the retainers.
- Bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding
.
- With the aid of an assistant, inspect the brake pipe flares for leaks
by starting the engine and applying the brakes.