Truck:
2003 Ford F150 4x4
4.6L V8
199k Miles

Issue:
Busted rear (steel) line. The one that connects under the truck along the rail above the fuel lines, all the way down the drivers side just by the gas tank. There a large hole that rusted through the steel line.

I have attempted to remove the line, but just cant get it to budge, about to go get some PB blaster, and coat it throughout the day.

The Problem is that I am looking towards an alternative to replacing the line altogether. I called Autozone and they sell the straight line, but I have to bend it myself. I am looking to see if there is an alternative, like buying some flex that will stretch from the rear connector to the front connector. And just run it along the frame like it does now.

I just need some opinions. I am worried that "IF" i get the original line out now, that it will not be intact, to even match up what to bend it to. Any cost effective ideas to fix the issue. I know penny-pinching it isn't the best, and buying the line and bending it myself may actually be cheaper than buying flex and connectors and rigging it. Just need some tips to get this stubborn bastard off, and get my truck going again.

 

I would replace with hardline and make the necessary bends. You would also need a flaring tool if you have to cut the hardline to shorten. Bending tube isn't difficult. There are a number of options.

What I use looks like a spring. It fits around the hardline to prevent the line from squashing. There are also many small benders available for cheap.

 

So i got the hardlines. Got all the fittings.

Turns out the factory line has a larger fitting on one end, and a smaller one on the other. So they gave me 2 lines, 4 fittings and a interconnect. Got it cut, flarred, assembled, bent.

I filled the reservoir, pumped the brakes a few times, Checked for leaks.

It is leaking right at the rear side of the nut that goes into the interconnect. So i would assume its the flare? I did single flares they set perfect, Should i cut it as close to the flare and try to re-flare that side? I am at a loss to still see this thing leaking.

Any tips please, has this happened before, is it the flare that caused it, other ways to fix it? Thanks in advance.

 

You need to use a double flaring tool on brake lines.