B. Replace Brake Tube(S)

1. Disconnect the negative battery cable from the battery.

2. Unsnap the radiator coolant overflow bottle from the radiator and set aside.

NOTE:
Do not disconnect any of the hoses from the coolant overflow bottle.

3. Remove the fastener that holds the power steering reservoir to the radiator core support and set the reservoir aside.

NOTE:
Do not disconnect any of the hoses from the power steering reservoir.





4. Separate the main wiring harness connector from the body support beam (Figure 3).





5. Disconnect the electrical connector at the canister purge solenoid (Figure 4).

6. Install a prop rod on the brake pedal to keep pressure on the brake system.

NOTE:
Holding the brake pedal in the applied position will isolate the master cylinder from the hydraulic brake system. This will not allow the brake fluid to drain out of the brake fluid reservoir while the brake tube is being replaced. This will facilitate bleeding only the rear brakes instead of the entire brake system.

7. Disconnect the brake tube(s) from the brake hydraulic control unit aluminum body (Figure 4).





8. Disconnect the brake tube(s) from the brass junction block(s) located next to the left frame rail (Figure 5).

9. Remove the brake tube(s) from the plastic routing clips.

10. Carefully remove and discard the original brake tube(s) from the vehicle.

CAUTION:
Use extreme care not to allow residual brake fluid in the brake tube to spill onto any painted surfaces while removing the brake tube(s) from the vehicle. Paint damage may occur.

11. Place the new brake tube(s) into position.

12. Connect the brake tube(s) to the brake hydraulic control unit aluminum body (Figure 4). Hand tighten the tube nut(s).

13. Connect the other end of the brake tube(s) to the brass junction block(s) (Figure 5). Hand tighten the tube nut(s).

CAUTION:
Each brake tube has a unique tube nut size. Be sure to install the correct size tube nut into the corresponding brass junction block threaded hole.

14. Snap the brake tube(s) into the plastic routing clips.

15. Tighten the brake hydraulic control unit tube nut(s) to 220 in. lbs. (25 N.m) (Figure 4).

16. Tighten the brass junction block tube nut(s) to 195 in. lbs. (22 N.m) (Figure 5).

17. Install the coolant overflow bottle onto the radiator.

18. Install the power steering reservoir to the core support.

19. Attach the main wiring harness connector to the body support beam (Figure 3).

20. Connect the electrical connector at the canister purge solenoid (Figure 4).

21. Remove the brake pedal prop rod from the vehicle.

22. Connect the negative battery cable.

23. Bleed the brake system using the following procedure:

a. Fill the brake master cylinder reservoir with DOT 3 brake fluid.





b. Attach one end of bleed hose to bleed screw on the rear brake caliper and insert opposite end in a clear container partially filled with brake fluid (Figure 6). Be sure that the end of bleed hose is fully immersed in brake fluid.

c. Open the bleeder screw on the rear brake caliper that had the brake tube replaced, then have an assistant press and hold the brake pedal down. Once the pedal is down, close the bleeder screw and release the brake pedal. Repeat the bleeding process until the brake fluid stream in the container is clear and free of air bubbles.

d. Repeat Steps 23a through 23c on the other rear brake caliper if both rear brake tubes were replaced.

24. Continue with Section C - Install Brake Tube Retaining Clip.