New air conditioning hose assemblies are expensive. Oftentimes, a simple repair can save hundreds of dollars. Repairing air conditioning lines falls into two categories. One is repairing aluminum fittings; the other involves repairing or replacing the rubber hose. In some cases, a simple A/C hose line splice is all that is needed while others require a complete hose rebuild. In either case, many auto parts stores and air conditioning service centers offer rebuild service.
Inspect the failed hose and either repair it on the vehicle or remove it for repair. If the repair can be made on the vehicle, cut the frayed or worn part of the rubber hose in two pieces. Insert a line splice and attach the hose clamps to secure the splice in place.
Remove the entire hose assembly from the vehicle to rebuild the unit. Replace one or both of the hoses if either has holes, is dry-rotted, cracked, brittle or softened by oil saturation.
Place the hose fitting in a vise. Use a hacksaw to remove the aluminum fitting crimp. Slit the exposed hose with a razor knife to easily remove the aluminum fitting. Measure the hose for the new hose replacement and cut the new hose to length. Insert new crimps over the replacement hose and insert the old fittings into the new hose. Place the new hose with the new crimp into a crimping tool and press down on the crimping tool handle. Repeat this process for each of the fittings.
Check the repaired hose for solid and tight fittings. They should not twist or move in any manner. Replace any in question before refitting them on the vehicle.
