OEM 2003 Chevrolet Malibu Brake Line

2003 Chevrolet Malibu Brake Line Parts and Q&A

• Q: How to replace the brake line using the ISO Flaring Kit (29803-A) on 2003 Chevrolet Malibu?

  A: When changing the brake pipe workers must use the ISO Flaring Kit (29803-A) with double-walled steel brake pipe to avoid brake system failures. The appropriate tubing and steel fitting nuts need to be procured for pipe replacement work followed by cutting the tubing to length which requires measuring the old pipe with a string and applying 3 mm (1/8 inch) addition for each ISO flare. Start by installing the fittings onto the tubing then flare the pipe by using the de-burring tool to chamfer both inside and outside diameters before removing all lubricants from the brake pipe along with the flaring tool. Place the tool body of the ISO Flaring Kit (29803-A) into a vise and add the necessary collet and forming mandrel according to pipe size before inserting the forming mandrel. Hold the mandrel while threading the forcing screw until it touches the mandrel and reverse it by one full turn. Position the clamping nut over the brake pipe onto the right collet then stop at 19 mm (3/4 inch) beyond the fitting edge. Drop the collet into the tool body until the brake pipe end rests against the forming mandrel face and tighten the clamping nut thoroughly. Twist the forcing screw until you reach its maximum rotation point without damaging it by over-tightening the screw. Finish flare procedure by first undoing the clamping nut and then separating the collet from the clamping nut. Bend the pipe to replicate the old pipe shape by preserving a 19 mm (3/4 inch) gap between all moving or vibrating parts.