GM 25906096
Flex Hose, Passenger Side

You need the J 45405 Pipe Flaring Tool Kit (J 45405) to fix brake pipes and should use double-walled steel brake pipe because single-layer pipes lead to brake system failures. First examine the brake pipe area and take off its retainers as necessary. In order to cut the brake pipe choose a reliable area that is free of bends and mountings to work in then measure the needed replacement length by summing up 6.35 mm (0.250 in) for 4.76 mm (3/16 in) pipes plus 9.50 mm (0.374 in) for 6.35 mm (1/4 in) pipes. Use the J 45405 (J 45405) device to cut the brake pipe straight and take out the sectioned segment. Insert tube nuts of the right size and use included J 45405 (J 45405) to strip nylon coating from one end. Use the same tool to chamfer inside and outside diameter surfaces of the sectioned brake pipe. Connect the tube nuts to the brake pipe then clean both the tube and J 45405 device. Finally loosen the die clamp screw. Adjust the die cage to accept the right die size and place the prepared pipe end inside before using the J 45405 (J 45405) lever to create the flare. Use a suitable brake pipe bending tool to form the new pipe when needed and check for proper flare shape and diameter before attaching it to the pipe assembly with brake pipe unions that should be placed 19 mm (3/4 in) away from all moving hardware. Connect the brake pipe to retainer elements then bleed the brake system hydraulic system before observing if fluid leaks from the brake pipe flares.

After removing the dies, inspect the flare diameter: 6.74-7.10 mm (0.265-0.279 in) for 4.76 mm (3/16 in), 8.57-9.27 mm (0.344-0.358 in) for 6.35 mm (1/4 in), and 10.42-10.79 mm (0.410-0.425 in) for 7.94 mm (5/16 in) diameter pipe.

Ensure proper routing and retention of the replacement pipes using the correct fasteners in their original locations to avoid damage that could lead to personal injury.

Take out the brake hose and bracket assembly.

Strip the nylon coating from the end of the brake pipe using the appropriate blade on the coating stripping tool, ensuring the metal surface is not gouged, and chamfer the inside and outside diameter of the pipe with the de-burring tool.

Disconnect the brake fluid level sensor electrical connector, the brake master cylinder reservoir return hose quick connect, and the supply hose quick connect.

Wait for the pressure relief to complete, then remove brake fluid from the reservoir until it is below the supply hose fitting and discard it properly.