Brake Pipe Replacement

TOOLS REQUIRED
- SA9193BR

ISO/DIN FLARE

CAUTION: ALWAYS USE DOUBLE WALLED STEEL BRAKE PIPE WHEN REPLACING BRAKE PIPES. THE USE OF ANY OTHER PIPE IS NOT RECOMMENDED AND MAY CAUSE BRAKE SYSTEM FAILURE. CAREFULLY ROUTE AND RETAIN REPLACEMENT BRAKE PIPES. ALWAYS USE THE CORRECT FASTENERS AND THE ORIGINAL LOCATION FOR REPLACEMENT BRAKE PIPES. FAILURE TO PROPERLY ROUTE AND RETAIN BRAKE PIPES MAY CAUSE DAMAGE TO THE BRAKE PIPES AND CAUSE BRAKE SYSTEM FAILURE.























1. Obtain recommended pipe and fittings of correct size. Outside diameter of pipe is used to specify size. Saturn uses 4.75 mm (0.187 inch) brake pipe.





2. Remove brake pipe to be repaired from vehicle.
3. Cut section to be replaced from brake pipe using an appropriate saw. Do not use a tube cutter to cut the new pipe; the end must be flat and square to produce a good flare.
4. Determine the length of pipe required for the repair by measuring the section to be replaced with a string adding 3.2 mm (1/8 inch) for each flare.
5. Cut new pipe using an appropriate saw. Do not use a tube cutter to cut the new pipe; the end must be flat and square to produce a good flare.
6. Remove the burrs from the inside and outside diameters of the cut pipe using a deburring tool.
7. Install required fittings.
8. Clamp Brake Pipe Flaring Tool SA9193BR (or equivalent) securely in a vice.
9. Install handle into operating cam.





10. Loosen die clamp screw and rotate locking plate to expose die carrier opening.
11. Select required die set (4.75 mm DIN) and install in carrier with full side of either half facing clamp screw and counter bore of both halves facing punch turret.
12. Insert prepared pipe through rear of die and push forward until the end of pipe is flush with face of die.





13. Make sure that the rear of both halves of the die rest against hexagon die stops. Rotate locking plate to the fully closed position and clamp die firmly by tightening clamp screw.





14. Select appropriate OR 1 (operation 1) punch by rotating punch turret until the correct size (4.75 mm DIN) points towards the open end of the pipe to be flared.





15. Pull the operating handle against the resistance of the pipe to create the Rare and return handle to original position.
16. Release clamp screw and rotate locking plate to the open position.
17. Remove the die set and pipe and separate by gently tapping both halves on a bench.





18. Inspect pipe flare for correct shape, size and any flaws.
19. Repeat procedure (steps 6 through 18) for pipe being repaired.
20. Bend pipe using an approved pipe bending tool such as SA91108NE (or equivalent), using the section to be replaced as a guide.
21. Install new pipe to pipe being repaired using female union.
22. Install repaired pipe assembly into vehicle.
23. Bleed brake system.
24. Check pipes and nuts for leaks with engine running and brakes applied.