How to Assemble Brake Lines & Fittings

Brake lines and fittings are usually something we look for a professional to handle, but now do-it-yourself mechanics can successfully assemble their own brake lines and all the fittings needed with brake line assembly kits. These kits include a long section of brake line, both male and female fittings and the manifold fitting, commonly called the banjo because of its shape. No special tools are needed besides a tabletop or bench vise to help secure the fittings correctly. They even include a vise wrench to help hold the brake line in the vise.

Instructions

1

Slip the female brake line fitting over the end of the -3 brake line hose. Cut the end of the hose between the black dashes with a pair of side cutters.

2

Insert the -3 hose into the end of the male brake line fitting opposite the end with the nut on it. Push it into the fitting until the first dash it comes to completely disappears under the sleeve of the male fitting.

3

Hold the hose and the male brake line fitting and insert the shaft of the banjo fitting into the end of the male fitting and into the hose. The banjo is the fitting that has a long shaft and a round end on it that has a hole in it. There is a line where the shaft of the banjo flairs out. This is called the witness line and it is instrumental in the proper assembly of the brake line and fittings.

4

Twist the end of the banjo until the threads on the banjo shaft clear the inside threads on the male fitting. This allows the banjo to turn freely inside the connection until it is time to secure it to the manifold.

5

Check the black dash on the hose to be certain the hose did not move during the installation of the banjo. You can also check the witness line on the banjo as well. It should be inside the male fitting.

6

Place the supplied vise wrench on the hex end of the male fitting and then place the assembly in a bench or tabletop vise. Push the female brake line fitting that you put on the hose at the beginning of this process up to the male fitting. Secure it to the male fitting with a 7/16-inch wrench until the hex end of the female fitting seats on the hex end of the male fitting.

7

Fit this end of the brake line in place, route the hose to the other end and cut it off between the dashes as before. Then repeat the process for this end of the brake line.