Brake Line removal/rounded nuts - Refurbed Calipers

[aj.extreme]

I've got a problem and could do with a cost effective option

I've just removed all 4 brake callipers and dropped them down to Big Red Brakes to get refurbed as MOT man said to get them looked at due to binding etc usual MR2 brake issues.

Whilst they are down there and the system drained of fluid i thought good time to fit some braided lines, brought a set from Brakes4U (thanks very much) Hel braided lines and went about getting them fitted ready for when i pick up the newly built callipers.

Now i got a brake line spanner and doused the nuts overnight in penetrating oil but when i tried to undo them they just completly mangled. The fronts came loose nicely and the Hel's went on no problems but the soft nuts on the rear lines just rounded and are in a right old state, i eventually got soaking them in oil and took a pair of monkey grips to them in the hope to loosen them off but nothing, would not budge. I had removed the bracket from the wheel arch liner and had a spanner on the bracket but it just kept mangling the brake line and bending it in all manner of ways. Before doing any serious damage i thought leave it and see what people here may have done with the same problem.

So i have a set of braided lines i'd like to fit to the rear but completely bug**red the soft copper? nuts (not sure of the correct word for them)

any help to get them undone very much appreciated, or any way of removing and fitting new ones. Failing i will just leave as is and sell the braided lines as i can see this being a bit of a mission.

Many thanks
Ajay

[going4the1]

Oh dear!

The rigid pipe nuts are a problem on all Toyotas. With all the vehicles I've had previously the pipes were badly corroded and needed replacing so destroying the nuts has never been an issue.

Unless you intend to replace the rigid pipe from the connector all the way to the master cylinder / abs unit I would leave well alone. (I don't think there are any other coupling points along that length). That said it's not a major job but you'll need a set of ramps and axle stands to lift the entire car of the ground to gain full access.

[aj.extreme]

What a pain

Why does one job always lead to 10 more lol. Part of owning an MR2 I guess, i did think about gettin the torch out and getting some heat into the nut? Anyone think that might give results?

I really don't want to start replacing the whole brake line as I can see that being alot of work for the sake of having braided lines. As it stands the join is good and just leaving in situe will cause no bother.

Would it be possible to hacksaw the line, fit a new nut and flare the pipe? Be a little shorter but not by much?

[ashley]

Get a heat gun on there then use the mole grips again

[vmaxnick]

What a pain

Why does one job always lead to 10 more lol. Part of owning an MR2 I guess, i did think about gettin the torch out and getting some heat into the nut? Anyone think that might give results?

I really don't want to start replacing the whole brake line as I can see that being alot of work for the sake of having braided lines. As it stands the join is good and just leaving in situe will cause no bother.

Would it be possible to hacksaw the line, fit a new nut and flare the pipe? Be a little shorter but not by much?

Hi
You can hacksaw the line and get a pipe joiner fitted. Your local back street garage will keep metric brake pipe joiners and double flare brake pipe tools
This is a totally acceptable way to replace damaged parts of brake pipes or where the pipe nut has been mullered. If the pipe is still long enough, you can just fit a new nut and get the pipe re-flared but you need a DOUBLE flare on a brake pipe, not thse horrible single flares you get from mickey mouse flaring tools, they aren't for brake lines despite being sold by auto factors.

[aj.extreme]

Thanks for the replies

I think I'll get the torch on them in the morn and see if they will budge, failing that will leave them fitted until the calipers are back on and bled then take the car down to my local mr2 specialist, a very good one that's best not mentioned ) and get the pipe cut and re-flared.

Thanks for the help, I'll update my goings on in the morn

[going4the1]

One point - The flaring tools sold as DIY work well BUT ONLY on the copper/nickel brake pipe sold 'off the roll' from motor factors.

I agree with Vmaxnick - The ONLY way to put a joint in a rigid (factory) pipe is by using workshop quality equipment.

Personally if you intend to fit your nice new flexi pipes then I would replace the entire length with 'off the roll' pipe.

Most motor factors will supply this 'to length' with the ends supplied and flared to fit. The only thing you need to do is to pre-measure the existing pipe 'end-to-end' and show them the flared profile. This type of rigid is very malleable and bends by hand. It will also outlast the life of the car.

Good luck

[aj.extreme]

Well a quick update

Thanks again for all the suggestions, i didn't try last weekend as the weather was awful and i'm in no rush, so today the sun is out and time to crack on

This is the state of the nut in question



It had been doused in penetrating oil all week so was hoping for good results, got the blow torch out and put some heat into the bracket part of the brake line/hose



Then attached the required tools of choice



And VOILA



Came undone very easily, albeit a bit messy and tatty i tidied everything up best i could and then got to work finishing what i'd started



Just got to figure out how to secure the lines to the wheel arch, may have to make a bracket from something, any suggestions? Pictures?

[Peter Gidden]

Get a second-hand brakeline and finish the job properly?

I and most other s/h specialists can have one to you by Tuesday.

[aj.extreme]

And on a plus note i pick up my new callipers Mon, all rebuilt and painted ready to go on with a fresh set of Greenstuff's

Whilst i was working away today in the carpark (i live in/run a pub) a red Rev1 turbo pulled up and we got chatting, ended up going for a spin in his car with the roof off.....lovely end to a successful day!

Glad i didn't have to bother replacing/chopping all the brake lines either!

[aj.extreme]

Peter i'm gonna bleed them on Mon and see if i get any leaks, if not will leave be for now as i've got a few other jobs i need doing first but yes i agree new lines will need to go on.

I recall a forum member saying you sold Poly-bush kits as i'm looking to do mine in the next few weeks (one of the above mentioned jobs) Any idea on a price? Not the engine mounts just the suspension F&R

Its a 95 N/A import

[Peter Gidden]

Peter i'm gonna bleed them on Mon and see if i get any leaks, if not will leave be for now as i've got a few other jobs i need doing first but yes i agree new lines will need to go on.

I recall a forum member saying you sold Poly-bush kits as i'm looking to do mine in the next few weeks (one of the above mentioned jobs) Any idea on a price? Not the engine mounts just the suspension F&R

Its a 95 N/A import

I'll PM you.

[abovetherim]

Well a quick update




Just got to figure out how to secure the lines to the wheel arch, may have to make a bracket from something, any suggestions? Pictures?

This is what i used

[aj.extreme]

Hmm looks good, was along the lines of what i was thinking off, just need to dig through the spare bits box, cheers

Anyway quick update:

Went to collect the callipers today from Big Red and they were not ready, got all the way there, the sun was out which meant i could spend the day getting them fitted but NO

They were suppose to call me Frid to let me know the pistons hadn't come in so wouldn't be ready for Mon (today) instead they have offered to post them out to me for free with a next day courier so hopefully i'll have them back this week and will get some pics up of the work carried out by the weekend. Ended up having all 4 wheels off and giving them a damn good clean, then gave the car a good wash and then gave the garage a good old clear out/tidy

Day not wasted but slightly disappointed, will update soon to those who are interested

[toxo]

Other manufacturers get the rear brake lines right, I don't get why HEL are still selling brake lines with no way of securely attaching them. It's well documented on here that HEL lines don't include the mounting bracket. Goodridge and others do!

Also, isn't the nut on your hard brake line still f**ked? How're you gonna torque it up enough that it doesn't leak if it's rounded to xxxx?

[aj.extreme]

Other manufacturers get the rear brake lines right, I don't get why HEL are still selling brake lines with no way of securely attaching them. It's well documented on here that HEL lines don't include the mounting bracket. Goodridge and others do!

Also, isn't the nut on your hard brake line still f**ked? How're you gonna torque it up enough that it doesn't leak if it's rounded to xxxx?

Well i know its not the best job in the world but like most MR2 enthusiasts we learn by mistakes and fix f**k ups as we go, i know that Hel lines are not as good as others but they were a lot cheaper and i like the fact that i have to make a custom bracket to fix them to the wheel arch, all adds to the fun of owning a 2nd car. The lines are pretty tight, granted i don't know if torqued enough but probably too much as i figured they won't be coming off for a fair while and if they needed replacing i might as well completely muller them tightening them back up, will see once bled and in use

[aj.extreme]

An update to those still interested in what i'm doing and in my choice to use Big Red -

A parcel arrived today (posted free of charge) and inside i found



They look pretty good, in fact i'd say better than brand new, had the callipers rebuilt, new seals, pistons, nipples, the worx as you can see and then coated in a polymer based paint that they offer in many different colours. Owning a red MR2 i went with the generic red, down to personal taste i guess

Anyway a few close ups









They look awesome and i can't wait to get them fitted in the morn, had the sliders/carriers done too as thought "well they are off the car so why not"

Any questions about cost please PM and i'll let you know, regarding the fitment and rebuild quality please keep checking back as i'll update my findings as i go

[platmatt8]

Pm'd and very interested!!

[aj.extreme]

Spent the morning fitting the callipers and pads today, they went on as easy (cough cough) as they came off lol

Look great and its nice knowing that the brakes are all sorted! Just got to keep it all clean now

[toxo]

I'm well impressed with the finish on those, they've done a great job.