Warning: Before starting work, please refer to the warning at the beginning Section 2 about the dangers of brake fluid.
Inspection
1. Apply the parking brake, jack up the vehicle at the front and rear and place it on supports.
2. After checking for signs of leaks in the pipe connections, inspect the flexible hoses for wear or other damage.
3. Carefully inspect the brake lines for signs of dents, corrosion or other damage. The corrosion must be removed and the tubes that have deep dents must be replaced with new ones. Corrosion is especially likely in areas underneath the vehicle where pipes are exposed and unprotected.
4. Replace all defective brake lines and hoses with new ones.
Removal
5. If any part of the tube or hose must be removed, fluid leakage when the filler cap is removed can be reduced by placing a piece of plastic over the filler neck and securing it with a rubber band. If the tube is to be separated from the master cylinder, the reservoir should be emptied by drawing out the fluid with a syringe. If brake fluid gets on the car body, it should be wiped off immediately.
6. To remove a section of tubing, secure the adjacent hose fitting nut with a suitable wrench to prevent it from turning, then unscrew the union nut at the end of the tubing to release it. Repeat the procedure at the other end of the tube, releasing the tube from the clamps securing it to the body. In areas where union nuts are exposed to the weather, they may be quite tight. If the nuts are designed for a fork-type wrench, then the edges of the nuts are standardized and, for this reason, to loosen tightly tightened nuts, it is preferable to use a split-end wrench, which engages all edges of the nut at once. If such a wrench is not available, you can use a self-locking wrench, although this is not recommended.
7. To minimize fluid loss when disconnecting flexible brake hoses, clamp the hose as close to the connector as possible using a patented brake high-pressure hose clamp. To remove the flexible hose, first clean the ends of the hose and the surrounding area, then unscrew the union nut from the end of the hose. After removing the spring clamp, pull the hose out of the serrated mount on the support bracket.
8. Brake pipes with flared ends and connecting nuts can be purchased either individually or in sets from Ford dealers or auto parts stores. Once purchased, bend the tube to the desired shape using the old tube as a guide - the tube is now ready for installation.
Installation
9. Installation of tubes and hoses is carried out in the reverse order of removal. Make sure all brake lines are securely supported by clamps and that the hoses are not kinked. Also, make sure the hoses are routed clear of all suspension components and underbody trim, and that they remain undisturbed by any suspension movement or wheel rotation. After installation, remove the plastic from the reservoir and bleed the brake hydraulic system as described in Section 2.