Section 06-00: Brake System—Service
1994 Mustang Workshop Manual
SERVICE PROCEDURES

Brake Tubing

 WARNING: COPPER TUBING SHOULD NOT BE USED IN A HYDRAULIC SYSTEM. WHEN BENDING BRAKE TUBING TO FIT UNDERBODY OR REAR AXLE CONTOURS, BE CAREFUL NOT TO KINK OR CRACK THE TUBE.

If a section of the brake tubing becomes damaged, the entire section should be replaced with tubing of the same type, size, shape, and length.

All the tube end connections at the brake master cylinder (2140) and brake pressure control valve (2B091) and anti-lock brake unit are ISO flare with metric tube nuts. These connections do not require brass tube seats. The ISO flare tube ends abut directly against the bottom of the outlet ports. All tube ends not at the brake master cylinder or anti-lock brake unit (if equipped) or brake pressure control valve are standard double flare with English tube nuts.







If a brake tube replacement is required at the brake master cylinder , the following procedure must be used.

NOTE: The metric nut will be reused.

  1. Obtain recommended bulk 3/16-inch steel tubing and correct tube nut.
  1. Cut tubing to length required. Clean burrs after cutting. The correct length may be obtained by measuring removed tube using a string and adding 1.2mm (1/8 inch) for each flare.
  1. ISO flare one end of the tubing using ISO and Brake Line Flaring Tool D81L-2269-A or equivalent.
  1. Place removed metric tube nut on the tube.

    NOTE: Follow flaring instructions included with ISO and Brake Line Flaring Tool D81L-2269-A or equivalent.

  1. On opposite end of replacement tube, install the English tube nut and double flare tube end.
  1. Bend replacement brake tube to match removed tube using a tubing bender. When replacement brake tube is installed, maintain adequate clearance to all moving or vibrating parts.

    All brake tubing should be flared properly to provide good leakproof connections. Clean brake tubing by flushing with clean brake fluid before installation.

    Always bleed applicable primary or secondary brake system after hose or line replacement.

    When connecting a tube to a hose, tube connector, or brake cylinder, tighten the tube fitting nut to specification with a Lb-In Torque Wrench D81L-600-A or equivalent.