Tips for Replacing Rear Hard Brake Line on Frame

So I went to replace my rear hard brake line along the frame because the flare nut was super seized up to the soft line and I couldn’t get it off without cutting the line.

I’m having a really hard time fishing the old hard line through the frame around the gas tank to replace it.

is it possible to loosen the gas tank straps and shift it to the side without dropping it/disconnecting anything?

In retrospect I should’ve just got a flare tool and put a new nut on after cutting the old nut off but it’s too late for that now so I’m committed to getting the new hard line in.

I was working with a headlamp in the dark so I’m hoping I have more success in the morning with some daylight.

does anybody have any tips or tricks? I’d appreciate any advice anyone has!

 

Well I struggled with it for 3 more hours today. Got the old line out but can’t get the new one around the rear cross member.

gonna just bite the bullet and drop the tank tomorrow.

 

Not really any tips for wrestling hard lines around when stuff is in the way.. Hang in there, you'll get it

 

Yeah, I should've just dropped the tank in the first place. Could've been done by now with all the time I wasted.

On the bright side at least I was lazy and didn't fill up when my gas light came on yesterday so I have an empty tank to make life easier.

 

See kids, laziness does pay off! Don't let anyone tell you different! But in all seriousness, thank God your tank was empty!

 

yeah I should’ve known better than following the vague advice from folks on here that said “I’m pretty sure you can snake it around the tank” but had no first hand experience doing it.

Only other post I could find on the topic was a guy with the same problem and then he followed up saying he got it without dropping the tank with no details of how he did it.

 

Why don't you take the bed off, it will make the job much easier and spare you from dropping the tank. Should be 4 bolts and the wiring in the back. Get a couple of buds to help you out.

 

because there is a wedge camper on my bed. Dropping the Tank seems way easier. A few hoses, 1 wiring connector and 2 bolts.



Plus I’m replacing the hard brake line inside the frame rail NOT the fuel pump. Coming from above the tank would still be in the way (line is next to the tank) and wouldn’t help at all. Would still have to drop the tank.

 

Shouldn't need to drop the tank all the way, just a few inches to gain enough room the maneuver the line through the frame. Support the tank with a hydraulic jack, which will give you precise height control.

 

I can tell you its miserable even with a bare frame. They ship the lines pre-bent, then they bend it again. Takes a lot of patience to get them looking oem factory.

Good job getting this done. For others, definitely drop the tank a bit. You can support it with ratchet straps.

 

ooh I love the ratchet strap idea! Totally gonna do that!

Maneuvering those pre bent lines is a nightmare. I’m replacing 47325. Definitely gonna have to do some clean up bending once it’s in place!

I already tried lowering it alittle without disconnecting the lines today and couldn’t get enough room.

 

If you take it to any independent shop, they'd just bend it to the rough shape using bulk line. I was stressing about it when installing sliders, until I realized I could bend the lines by hand to clear the fasteners. Cut a slit along the length of 1/4" fuel hose and slip it over potential chafe areas.

 

oh yeah I know it’s totally bendable and not worried about it. It’s more that I already got the pre-bent line from toyota and it is an interesting exercise snaking it down the frame rail.

 

Dropped the tank today and got the new brake lines in. Even with the tank out it was a massive pain in the ass to snake the pre-bent hard line though the frame. If I were to do it again I’d just get bulk straight line and a flaring tool. It would’ve been way easier to route through the frame and then bend since I had to re-bend everything once it was routed anyway.

I don’t see how this would have been remotely possible without dropping the tank.



Dropping the tank wasn’t nearly as bad as people make it sound but it wasn’t very fun. The hose and wire harness on top are a pain to get off. It took about 1.5 hrs to get it out but only 15 mins to get it back in.

I’m glad I’m done with this and hope to never do it again.

 

Thanks for the follow up & closure post here. Sounds like one of those "thank God that shit's over with" jobs.

 

I have installed numerous new brake lines .

My method tape the end to keep the dirt out wiggle past all the obstacles .I also go front to back

Cut as much of the old brake line out as I can reach any of the clamps have long been broken off.

secure as needed if lines look to rub a old piece of fuel line

This newer Copper nickle line is a joy to work with it bends and flares so easy.

I have yet to ever make a double flare without it cracking on old exposed brake line.

 

Happy to follow it up. I hate it when people ask questions about their problems but don’t follow up with how they solved it.

And 100% a glad I’m done with it kind of job

That’s pretty much exactly what I did.

The biggest pain was wrestling the pre-bent line though the frame around cross members. Especially the last 2 feet to the rear, some sections pretty much got straightened out to fit through the frame and then I had to re-bend back into shape. Straight line would’ve been way easier to route and then bend in place. The pre-bends made it harder to get through in a lot of spots.

 

I see the difference I have been making my own brake lines for 40 years.

i can see having a prebent line would be a royal pain.

My brake lines I bend as needed once it is more or less in place.

That Copper Nickle line is so easy to work with.

 

Don't get me started, one of my biggest pet peeves. A lot of folks with a "take take take" mentality who don't give back. Even if it's just trivial repairs/maintenance/issues, it can't hurt to bring closure as it just adds to the ever growing database of knowledge here on TW. You never know what average Joe it may help down the road who stumbles across your thread/posts.

 

I found like a dozen of those threads on this topic searching before I posted this one where they posed a question and then it either went dead or they just followed up with “figured it out” and no details.