Replacing brake hard-lines

I need to replace my front hard lines going to the brakes (1990 4.0, AW4, etc.). What is the easiest way to do this and what do I need to remove in order to access the block in which the lines run (below the master cylinder).

You can get at the hard lines on the block below the master cylinder if you remove the air cleaner box. It's still a tight squeeze, but can be done with patience.

Replacing hardlines is a PITA, but if they're rusted inside there's no alternative. If it's just a crimp or two, it's usually easier to cut out the crimped section, install fittings on the clean tube ends, and install a flex hose between the ends.

For doing tubing, you'll need a bender with proper jigs, seamless steel (not stainless) tubing of exact size, and flaring tool with fittings.
Buy extra tubing and fittings, and practice to get a feel for the tool to avoid crimping your final lines.

The PITA is measuring and placing bends in just the right places, at just the right angles.
You can cut-out the old lines, then use them as a pattern to make the replacements. Since they bend in three dimensions, getting the new lines to match isn't easy.
Above all, keep the ends securely plugged and avoid all contamination. A single grain of sand will eventually plug a tiny passage.

Check with NAPA, they might have pre-fitted replacement tubing available for your XJ by special order.

Dealer is pretty cheap

I just got some new lines from the dealer. Less than 20.00 for the two fronts bent and ready to install. There are still quite a few available
Dustin

Re: Dealer is pretty cheap

LT1XJ said:

I just got some new lines from the dealer. Less than 20.00 for the two fronts bent and ready to install. There are still quite a few available
Dustin

Click to expand...

Post this in your diary!!

That's the smokin'est deal you'll ever see from DC!!

As far as lines go I can just take my old ones in and have them made for me as I wait. My main concern was how the heck do I get access to the old lines and what size are the fittings (what size wrench?).