Mitsubishi Montero & Montero Sport This sport utility vehicle offers more size than the other Mitsubishi SUVs, but manages to keep a sporty look and comfortable feel, unlike many larger SUVs.

How to replace Rusty Brake Lines

  #1  
Old 04-05-2019, 05:39 PM
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Default How to replace Rusty Brake Lines

I have a couple 94 Monteros which desperately need some new brake lines. The salt roads have not been nice to that blend of copper/nickel making up those brake lines:




Ready for a pressure test of those lines?:






My question to the experts: I want to buy a couple 25 foot rolls of copper/nickle brake line and need to know what diameter will fit. Is it a metric brake line, or a standard 3/16? Also, where do I buy boxes of the male/female connectors so I can flare the brake lines and use new connectors? I have the flaring tool kit, and just need to order the lines and connectors.

Another thought......Does anyone sell a complete kit of replacement brake lines for these old Monteros?

Thanks.
 
  #2  
Old 04-06-2019, 05:23 PM
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OK......Did some homework. There are no specs in the big Mitsie Shop Manuals on the diameter of the brake lines. Nothing online either. So I just used my calipers to measure the OD of the lines......came out to be 3/16".

I found a good supplier on Ebay for 25 foot rolls of solid copper (not that steel with copper plating), and they also had metric fittings. Their name is: Inline Tube. Here is a sample of what they provide:
You will need a simple flaring tool kit, which can also be found for about $15 on ebay.

 
  #3  
Old 04-07-2019, 09:10 PM
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Wow, that is the most rusted brake lines I've ever seen. Glad you were not driving downhill with those. I think your plan to just use bulk tubing is the best, since it will be nearly impossible (or prohibitively expensive) to replace individual lines with OEM or pre-made kits. I quickly checked couple sites from where I order parts. They don't have metal lines, some do stock short rubber hoses that you need between the body and the axles.
 
  #4  
Old 04-08-2019, 12:12 AM
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Default Thoughts...

Double check to make sure those are not double flare or inverted flare at the fittings. The same engineers who developed the 'bunch of bananas' intake for the twin cam, and the myriad vacuum line systems were the same ones on all of the other systems on these trucks.

Once you figure it out, let the rest of us know, lol!!!
 
  #5  
Old 04-08-2019, 07:07 AM
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Hunter......Yea, those rusty lines look like 20 year old spagetti roasting in the hot desert sun, and its so nasty looking that even the vultures and wolves stay away from it. Amazing that there is only one leak (so far), and thats between the rear pumpkin and the right rear brakes.....all the others are begging to pop loose and spew, but are still holding. But like you said, take a long trip down a mountain pass, and a bit more foot pressure and she will be popping and spewing, sounding like a pop-corn maker.
 
  #6  
Old 04-08-2019, 07:11 AM
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Originally Posted by Marksroberts61 View Post
Double check to make sure those are not double flare or inverted flare at the fittings. The same engineers who developed the 'bunch of bananas' intake for the twin cam, and the myriad vacuum line systems were the same ones on all of the other systems on these trucks.

Once you figure it out, let the rest of us know, lol!!!
Mark......Oh no! Double flare/inverted flare???? What the heck is that? Im hoping they are just plain jane single flare.

Vacuum lines, and other lines.....Yea, looking above the gas tank, I see lines running all over, and Im guessing they are just EPA mandated lines to capture vapors......let em rust! But the fuel lines pumping fuel may need to be watched. Ive been spraying PB Blaster on all the fittings in anticiipation of doing repairs.
 
  #7  
Old 04-08-2019, 08:41 AM
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Default Fuel lines

That NiCo tubing is really easy to form and can be beautifully polished, if that's your jazz.

The fuel lines are a pain! The short rubber one from the top of the fuel pump bracket to the hard line is $115 from the dealership and no other source... fuel pump bracket with pump is about $750 from Mitsu, but I'm getting one from China for $100, throwing away the pump from it and installing a $70 Delphi pump from AutoZone. Sometimes you have to pull an end run on the dealerships.
 
  #8  
Old 04-08-2019, 04:07 PM
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Mark......Well, I bought the copper since I thought it would last longer and bend easier.....not worried too much about seeing a nice shine, but that sure beats all this "rusty spagitti" down under.

Fuel lines.....I agree....no way I will pay 750 for the fuel pump bracket and pump.....I will also do some "jerry-riggin" if that problem presents itself. (Another reason to have a cheap parts rig to rob from).
 
  #9  
Old 04-08-2019, 04:44 PM
Join Date: Mar 2019
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Default Donor cars

The crazy ex-girlfriend and I had a couple of donor rings, came in really handy when we upgraded her LS to a rear locker!
 
  #10  
Old 04-08-2019, 06:18 PM
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mark......I hear you about those "crazy" ex-gal friends. But you put those donor rings to good use.
 

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