Question about 1996 Mercury Cougar XR7

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Brake line replacement

Replacing all brake lines&hoses due to rust. need to know fitting sizes to begin this project without dismantling everthing, (only car).ex.:brake bleeder screw supposedly 3/8" 24 thread 1" help avail. to me without bringing in parts which ends my transportation. great car! any other help you can give me for this project would be great,will be replacing with copper lines,etc. i have tools and yr.'s shade-tree' cougar xr-7 3.8 with rear drum brakes

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What i usually do if the money is available is purchase the brake lines in all sizes from the auto parts store and return any unused parts to the auto parts store,for a refund. they usually know the sizes you need ; you could also do the front first then the rear, or replace one line to get the size, also need a tubing bender to bend the brake lines, 'bleeder screws are usually three choices or go to ford or mercury, once you get started its not too bad, beware of compression fittings (unsafe to do it that way) Good Luck .

Posted on Sep 17, 2009


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Related Questions:

1 Answer

How easy is it to replace a leaking driver's brake line on a 1995 cutlass ciera?

In most cases on these older GM vehicles it is much easier to replace the lines from the master cylinder all the way to the rear wheels. You should be able to find brake lines that are preferred and have the correct fitting for what you need to do. Compression fittings are a definite No No

Some things to check ahead of time
1. Do all the bleeder screws open? If not you may be replacing wheel cylinders and calipers.
2. Are the brake hoses cracked? If they are might as well replace them at the same time.
3. Are the pads and shoes in good shape. If they are getting thin might as week replace them as well.
4. Do all the brake lines you need to replace come loose from the hoses, cylinders, master cylinder, proportioning valve, etc.

Just about every GM that I get in the shop with rusted brake lines to the rear end up with a $800 +/- bill. 3 hours labor, 20+ feet of line, proportioning valves (later models), fittings, wheel cylinders. And a bleed and flush.

The lines don't have to look pretty they just have to work!

good luck and let us know how it goes.

Sep 19, 2014 | Cars & Trucks

2 Answers

How to replace a brake line ?

Steel tubing or rubber flex hose?

What line,where,how long,where does it go-- to end for end

Rubber Hose is just unbolted

Steel tube is unbolted and if necessary cut out & new
tubing has to be cut to size,flared & bent to fit

It is a fabrication job few folks have the patience or skills
for,not many auto repair people do,not the pros

Jul 26, 2014 | 2000 Oldsmobile Intrigue

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I have a 1996 Ford Taurus. The long brake lines that run under the driver's door are rusted out. Neither the dealer or local auto parts chains seem to carry the lines. I would like to know what size these...

There has never been brake lines made,ever,for any vehicle

I'am surprised, a little, with your question

I would think, any auto parts store, would have taken you to
the side of the counter and offered to show you all the tubing
and got out a box of fittings

They are 3/16" steel brake tube
You have to fabricate your own

You need to cut,bend and flair the tubing,
to replace the rusted part or however far
you want to take the project

I could write a book here, to help you,but have other people
to get pointed in some direction. Let me know what help I can
be. I have done lots of brake line fabrication. Just as a note:
The repair shops hate that job, and butcher it

Dec 02, 2010 | Ford Taurus Cars & Trucks

1 Answer

I put new rotors and front pads on and now i have no brakes in the front iam going to replace the brake lines to the calapers and bleed the brakes .. is there a paporation valve in this car i should check ...

What happened to the brakes,? Did you have them before you started this project? I don't think the lines need to be replaced. I would only do that if they were leaking or damaged. Your proportioning valve going bad is rare. Is there any rust under there? Are the pistons on the calipers rusted? Did they readjust to the new pads? Did you move them to fit the new pads? How about the flexible hose? Is it in good shape? Try bleeding what you got before you start another project. Make sure they are moving, you might be needing to hone the pistons on the calipers. Hope this helps.

Aug 06, 2010 | 1998 Saab 900

3 Answers

How do you change the rear brake line that goes between each wheel, the brake line that is metal..

Don't do this unless you have skill at and tools to repair flair pipe. You will need the special tubing wrenches as well. The fittings/pipe are probably rusted and - frankly - it will be a night mare getting the repair done ... and then the 'fun' begins when you try to get the air out of the line.

Mar 19, 2010 | 1999 Chevrolet Blazer

1 Answer

Clip holding brake hose to chassis

That clip is just rusted. Use a hammer and chisel putting the chisel against the leg of the clip and work it out. Spray it down with penetrate.

Don't remove that until you have removed the metal line going in. try a little heat on the metal line and work it. It is in your best interest to get that to turn out, and often the line rusts to the fitting causing it to twist off and brake. What ever you do, do not use compression fitting if it breaks. they make brake lines that will go to the master with the right fittings depending on how far you have to go.

Hope this helps

Nov 24, 2009 | 1993 Ford Ranger SuperCab

1 Answer

I need to replace the right rear brake line as it rusted out. What size are the lines and fittings?

Your best bet is to get the line at an auto parts store. The line would be correct in size and bent correctly for easy installation with fittings included. That takes all the worry about building your own line.
Hope this helps... Good luck!

Oct 12, 2009 | 1993 Buick LeSabre

1 Answer

How do i replace rear brake line on a 1989 ford f150

This is a pain job. Wear safety goggles, as you will probably have rust falling down on you as you work. The brake line fittings will be difficult to separate. Soak the fittings with some penetrating oil for several days to make them easier to take apart. Get a pair of vise grips on the fitting that you want to loosen, and another pair where it attaches to the next line. Make sure the line you don't want to change doesn't turn, as it is common for the lines to be fused together with rust, and many times the 'good' line breaks off at the connection, requiring you to replace more lines. Parts stores have different sizes and length brake lines, and they are quite cheap. Bring the old line in for them to match up the fitting size on both ends and the length. You will have to bend them to match the original, just do it slowly so you don't 'kink' them (they are junk if that happens, and you will have to start over). You will then have to bleed the brakes to remove air in the lines. Good luck.

Oct 06, 2009 | 1989 Ford F 150

1 Answer

My rear wheel brakeline on durango 1998 blew

Depends on your mechanic ablilites. Steel brake line is basically 0.188 inch diameter line, and the metric 6mm line dia is very closely same.
Dodge uses ISO bubble flare , and not the American standard double flare at the end of the steel tube line. This ISO bubble flare on the steel line then fits into its mate female end which is the rubber hose connector end.
So, easiest way to get rid of the ISO bubble flare and change to American double flare end is:
Some automotive stores such as Parts Plus Auto Stores carry the brass brakeline adapter which has one end being the male end that fits nicely into the rubber hose with its ISO bubble female fitting, while the other end of the brass line adapter is the female end which has the double flare so you can then insert the steel line replacement with standard double flare into this end of the adapter.
Steel line , bungy brake line or equivalent is fine, and has the brake line nuts already on it, and is flared for you too. If you want to stay with ISO bubble line fittings you can get that in bungy brake line lengths too but it is less common for some stores to carry, and that is why the conversion brake line fitting adapter mentioned is so easy a way to change from ISO bubble flare to a double flare for easier use of all steel line being standard American double flared brake line. The brake lines come in straight lengths, 2ft 4ft, and 6ft, so you can use them to fit your necessary total length by connecting them with tubing couplers which the steel tube lines brake line nut gets threaded into.
My same year Durango had its rear line blow thru last year, due to the rusting of the steel brake line. I just got done last week, doing a entire steel line replacement myself. It was a medium sized effort for sure. You should check the other lines for the entire brake system to see if you need to replace more than just that section which failed for you, as my lines showed heavy corrosion at many other locations in the brake line system.
It is easy to double flare brake line tubing , and Sears sells its craftsman brand of brake line double flare tool kit for that purpose at about 60 bucks if I recall it right.
One thing you should do when doing your own double flaring, is to use a dial caliper to measure the diameter of the flare at its widest flared end, to insure you are within the required diameter of flare to insure proper sealing when you tighten down the tube flare nuts. I recall the flare diameter is supposed to be 0.272 inches , plus or minus 0.006 inches ( so range of dial caliper measuring of that formed flare should be between 0.266 inch and 0.278 inch) to insure the right diameter of flare for good sealing.
You can also get steel galvanized tubing line in coils of 20ft and more, with a bunch of brake line nuts ( all this is standard american brake line nuts, for double flared line fitting) from Inline Tube company;
Check out the great tech info from FEDHILL website,
Good luck, I did it so you can do it and feel satisfied and safe for the family with solid and sound steel line that is much better than chancing an accident via leaving the rusted line in place.

Aug 02, 2008 | 1998 Dodge Durango

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