How to Repair Steel Brake Lines

If you want to keep a vehicle for as long as possible you will need to be capable of doing your own repair work. Otherwise, the local shop is likely to charge huge repair bills to fix problems that are more involved than just parts replacement.


An example is a leak in the steel brake lines. A shop would likely want to replace all the brake lines, at a cost that may actually be more than the vehicle is worth. But a skilled do-it-yourselfer can cut out the bad section and replace it with a section of new line, at minimal cost.

Things You'll Need

  • Dremel tool with cut-off wheel
  • Wire brush
  • Double flaring tool kit
  • Brake fluid
  • Patch line section with flares and nuts installed
  • 2 flare nuts
  • 2 flare unions
  • Flare wrench set
  • Cut the bad section out of the line, using the Dremel. Unlike a tubing cutter, the cutoff wheel will not work-harden the tubing. Make the cut section the same length as the patch section. Pre-made patch sections are available in various lengths at most automotive parts stores.

    Clean both cut-off ends of the brake line with the wire brush.

  • Slip a flare nut onto one of the cut-off ends, with the threads pointing towards the cut.

  • Place the tubing clamp from the flaring kit on the cut end. Use the small anvil from the flaring kit to gauge the proper amount of line to leave protruding. Check that the flare nut is still on the line behind the clamp, then tighten the wing nuts on the clamp as tightly as possible.

  • Place a drop of brake fluid on the end of the tubing to lubricate it. Put the anvil disc over the end of the tubing and hold it in place while you place the flaring tool on the clamp. You may need to back the bolt out of the flaring tool so it will fit.

  • Tighten the bolt on the flaring tool to press the anvil disc into full contact with the clamp. Then back the bolt out and remove the anvil disc.

  • Tighten the flaring tool into the partially formed flare to finish forming the flare. Then loosen and remove the flaring tool and the clamp. Slide the flare nut down to the flare.

  • Repeat Steps 2 through 6 for the other cut-off end of the brake line.

  • Place a flare union on each end of the patch line section. Thread the flare nuts into the unions and tighten securely with the flare wrenches. Then use the patch to replace the section of brake line that you cut out. Thread the flare nuts which are on the cut-off ends into the flare unions, and tighten securely.

  • Pour brake fluid into the master cylinder reservoir, and bleed the brakes.