How to Replace the Brake Lines in a 1996 Plymouth Voyager

If any of the metal brake lines on your 1996 Plymouth Voyager are punctured or otherwise damaged, it will cause fluid to leak and you'll need to replace it. The metal brake lines are made up of multiple steel pipes connected together, and replacing a line is much like changing one on any other vehicle, save for the exact shape the pipes are bent in. Always use steel brake lines and never copper ones, and look for brake lines that are already flared at the ends for easier installation.

Instructions

1

Raise the van at the end closest to the brake line you are servicing and support it on jack stands. Remove the wheel.

2

Clean all dirt and contaminants away from the brake line fittings using compressed air.

3

Disconnect the metal brake line at both ends with a flare-nut wrench, making sure you don't bend the frame bracket or the line at either end, especially near the rubber brake hose.

4

Bend the replacement brake line to the exact same shape as the old line using a tubing bender. You may be able to find brake lines bent to the same shape needed for the 1996 Voyager.

5

Install the new brake lines in their fitting and the brackets on the Voyager's chassis, making sure there is enough clearance between the lines and all hot/moving components. Tighten the fittings on the lines with the flare-nut wrench.

6

Fill the brake master cylinder with fresh DOT 3 brake fluid. Bleed the brake system at the wheel for the line you changed. If the line you changed was connected to the master cylinder, bleed all four brakes.

Bleeding the Brakes

7

Connect a small piece of rubber tubing to the bleeder screw on the brake caliper and submerge the tube's other end in a container partially filled with brake fluid.

8

Open the bleeder valve while a second person presses on the rake pedal inside the van. Look for air bubbles to appear in the container, then close the valve and have the assistant release the pedal. Repeat until all air is purged.

9

Reconnect the wheel and lower the van off the jack stands.