How to Repair a Broken Brake Line

A broken brake line can be caused by severe climate, such as snow. The salt that is used to melt the snow can lead to corrosion of the brake line. Once the damage is discovered, the entire brake system should be inspected. A broken brake line can be repaired by the vehicle's owner. The tools and materials needed to repair a broken brake line can be purchased from most local auto parts stores.

Preparing the Vehicle

• 1

  Raise the vehicle with a floor jack and place jack stands beneath it for support.

• 2

  Inspect the brake lines. Check the lines for corrosion, leaks and rust.

• 3

  Determine how much brake line is needed for the repair with a measuring tape. Add 6 inches to the total measurement to leave room for any errors.

Repairing the Entire Brake Line

• 1

  Soak the connectors with rust penetrant. Use a line wrench to remove the brake line fittings.

• 2

  Use a tube bending tool to bend the new brake line. Be sure to match the new line with the old line. The bends in the line prevent strain on the line while driving. Lay the lines side-by-side to compare them.

• 3

  Install the new brake line. Tighten the compression fittings with a line wrench.

Repairing a Section of Brake Line

• 1

  Use a hack saw to remove the damaged section of brake line. Measure the old brake line with a tape measure. To compensate for the compression fittings, cut the new line 1/2 inch shorter than the old line.

• 2

  Press the compression fitting cap onto the brake line, moving it up 2 inches.

• 3

  Install the ferrule, a ring inside the cap that helps align the brake line with the compression fitting. Place the center section of the compression fitting onto the end of the brake line. Push the center section onto the brake line and install the cap. Tighten the cap as much as possible by hand. Use an open-end wrench to completely tighten the cap while holding the center section. Repeat the same process for the other side.

• 4

  Bleed the brakes. Fill the master cylinder with brake fluid. Attach a vinyl tube to the caliper's bleeder valve. Place a drain pan under the valve. Open the valve and have an assistant depress the brake pedal until brake fluid flows out of the tube. Close the bleeder valve and remove the tubing.

• 5

  Refill the master cylinder with brake fluid. Start the engine and slowly pump the brakes, pausing every few seconds when the pedal reaches the floor and while the brake pedal releases. Turn the engine off. Inspect the brake lines for any signs of leaks.

• 6

  Use the floor jack to raise the rear of the vehicle then remove the jack stands and lower the vehicle to the ground.

• 7

  Test the brakes to ensure proper brake line installation before attempting to drive on a public road.