How to change brake lines of your Jeep

The following is a write-up adapted from the website http://www.4x4xplor.com/TJ-brakelines.html, when I was planning to replace my own brake lines by Goodbridge. However, I did not ever find an opportunity to do this with one big reason being the expensive GoodRidge brake lines.

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How to change brake lines of your Jeep

What You Will Need

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• Goodrich Stainless Steel Extended Brake Lines
• Copper Crush Washers
• Retaining Clips
• 9/16" Socket
• T-40 Torx Bit
• 3/8", 1/2", 11/16" Flare Nut Wrenches
• DOT3 Brake Fluid
• Ratchet
• Rag
• Brake Bleeding Kit (vinyl hose and jar works)
• Brake Bleeder Wrench
Installation

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1. Open your new stainless steel brake line kit and make sure you have all the parts you need to complete this job prior to doing anything else. It is absolutely essential that you have NEW copper crush washers. If you don't, go to your local auto parts store and get them now.

2. Park your Jeep on a level surface and then turn your steering wheel until your tires are pointing completely to the left. This will allow you better access to the passenger side of your front brakes.

3. Assemble the brass fittings (finger tight for now) onto your brake lines as shown in the pic to the right. Take notice how the bend on the rigid end of the brake line is parallel to the flat sides of the brass fitting. (Figure 1-2)

4. Using a 9/16" socket, remove the banjo bolt securing your OEM rubber brake line to the caliper. This will be a bit messy so be sure to have some rags handy. (Figure 3)

5. Now, using a 3/8" flare nut wrench, loosen but do not remove the nut on the hard line attached to your frame as shown in the pic to the left.(Figure 4)

6. Remove the Torx bolt and retaining clip securing your brake line to the frame using a T-40 Torx Bit and then remove the OEM rubber brake line from it. Again, be sure to have some rags handy. (Figure 5)

7. Clean off the banjo bolt of any debris or gunk and then slip it through the brass fitting on your new brake line with a NEW copper crush washer on either end as shown in the pic to the right. (Figure 6)

8. Check to see if there is an old copper crush washer sticking to your brake caliper. If there is, pick it off and clean the surface around the hole of any gunk. Now, fasten the banjo bolt to the caliper (as shown in the pic to the right) securing the brake line to it. It is important to tighten the bolt enough so that the copper washers get crushed but take care not to over do it.

9. Using a 1/2" flare nut wrench, fasten the nut attached to the brass fitting with the banjo bolt going through it. Take care not to over tighten these parts as they are only brass and can be stripped easily. (Figure 7)

10. Now, using a 3/8" and 11/16" flare nut wrench, attach the upper part of your new stainless steel brake line to the hard line attached to your frame. (Figure 8)

11. The kit came with two rubber jacketed retaining clips but the bolt holes were a bit too small to fit the OEM Torx bolts. Needless to say, we had to widen up the holes using a Dremel with a grinding bit before proceeding.

12. Attach your retaining clip to the hard line attached to your frame rail using the OEM torx bolt as shown in the pic above.

13. Repeat entire process on the driver side of your Jeep.

14. Bleed your brakes.

See the link bleeding your brakes.

15. With your engine on, pump your brakes and then hold them down for about a minute. Shut your engine off and check for any leaks.

Cited from http://www.4x4xplor.com/