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So.. Going on week 2 of my new to me 1999 F350 w/ 115k on the clock. Doing the routine fix and repair stuff. Did the drivers side hub rebuild last week and doing the passenger side this week. Did the front brakes over the weekend, no issues except for a frozen caliper pin, got it unfrozen and anti seized everything. So today I'm underneath there to grease the u-joints and behold my next repair. The previous owner had cut the rear brake line and crimp it off to avoid losing fluid/pressure.
Long story short, the hard brake line was rusted through by the fuel tank. I bought all new calipers, rotors, pads and going to compression union (1/4") into the good portion of the existing brake line by transmission and run new stainless line on back. I was going to use 316 SS .035 wall as we have it in our shop. Is this a common rust area? I can't wait to see how it stops w/ 4 disc brakes, instead of just the 2 fronts!
My truck looks good there, but it had undercoating shot everywhere by someone who owned it before me. Now i get to clean off all the undercoating and use primer and paint method to prevent rust for a couple years. I did that with my brakes once, my RR caliper was stuck, so i took it off, and i couldnt run the truck without the caliper since it would leak fluid, so i capped the line so i could get back on the road and the next day fixed it.
I bet having all four would be nice since you've been on two. One thing I've noticed on these trucks is everything seems to be a corrosion area. When I bought my '01 new right off the transport, the under side had a nice thin coat of corrosion. So far no worries with the brake lines, but I know others here at FTE have. They are pretty thin. I guess it depends on the climate you're in and the chemical du Jour in your area.
One thing I need to say is never ever use compression fittings on brake lines.
The line pressures can exceed 1500 lbs and blow the fitting apart. If you're wanting to save a little $$ brake lines aren't where I would do it. If you're set on cutting and connecting the SS I would flare them. You need to double flare the steel and only single flare the SS. You might be fine with compressions since you're already running around with no rears anyways, but why not just fix it right this time and be done with it for good?
Hopefully some others will give you their feelings on comp. fittings. I just wouldn't go there if it were me.
Long story short, the hard brake line was rusted through by the fuel tank. I bought all new calipers, rotors, pads and going to compression union (1/4") into the good portion
You should use a double flare for brake lines. Using a compression fitting is not advisable although it would be better than the crimped line you found. It's OK for a temporary repair but may pop at the most inappropriate time (hard braking) and cause rapid pedal drop, loss of brakes and skid marks in your shorts.
the compression fittings I'm using are good up to 5000 psi. It's a swagelok fitting (double ferrule). Right now I have a compression union on it w/ a cap. So far no leaks and better pedal feel.
Going to pick up the inverted nut tonight to connect to the rear soft "rubber" lines and then do this all tomorrow. Hope to have good news to report!