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HOMESERVICE MANUALSPONTIAC2008GRAND PRIX BASEREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 425 (HYDRAULIC BRAKE SYSTEM)REPAIR INSTRUCTIONSBRAKE PIPE REPLACEMENTREPLACEMENT PROCEDURE
2008 Pontiac Grand Prix Base

Replacement Procedure

2008 Pontiac Grand Prix BaseSECTION Replacement Procedure
WARNING: This page is about a different car, the 2008 Buick LaCrosse and 2008 Buick Allure. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Sectioning Brake Pipe Using Pipe Cutter
    GM900937Courtesy of GENERAL MOTORS CORP.
  1. Inspect the section of brake pipe to be replaced.
  2. Release the brake pipe to be replaced from the retainers, as required.
  3. Select an appropriate location to section the brake pipe, if necessary.
    • Allow adequate clearance in order to maneuver the J 45405  . See Special Tools .
    • Avoid sectioning the brake pipe at bends or mounting points.
  4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends.
  5. Add to the measurement taken the appropriate additional length required for each flare to be created.

    Specification:  6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe

    IMPORTANT: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe length.
  6. Using the pipe cutter included in the J 45405  , carefully cut the brake pipe squarely to the measured length. See Special Tools .
  7. Remove the sectioned brake pipe from the vehicle.
  8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake pipe size.
    9. Fig 2: Stripping Nylon Coating From Brake Pipe Ends
    GM900939Courtesy of GENERAL MOTORS CORP.
  9. Strip the nylon coating from the brake pipe ends to be flared, if necessary.
    • Select the appropriate blade on the coating stripping tool included in the J 45405  , by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers. See Special Tools .

      Specification:  6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe

    • Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers.
    • While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface.
      IMPORTANT: Do not gouge the metal surface of the brake pipe.
    • Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges.
    • After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed.
    • Loosen the thumbwheel of the tool and remove the brake pipe.
      IMPORTANT: Ensure that all loose remnants of the nylon coating have been removed from the brake pipe.
    • Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been removed.

      Specification:  6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe

    10. Fig 3: Chamfering Pipe Using De-Burring Tool
    GM900947Courtesy of GENERAL MOTORS CORP.
  10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J 45405  . See Special Tools .
  11. Install the tube nuts on the brake pipe, noting their orientation.
  12. Clean the brake pipe and the J 45405  of lubricant, contaminants, and debris. See Special Tools .
    13. Fig 4: Installing Die Halves Into Die Cage
    GM900942Courtesy of GENERAL MOTORS CORP.
  13. Loosen the die clamping screw of the J 45405  . See Special Tools .
  14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the counterbores of both dies facing the forming ram.
    15. Fig 5: View Of Clamping Screw & Unused Die
    GM900943Courtesy of GENERAL MOTORS CORP.
  15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies.
  16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1).
  17. Remove the unused die (1).
  18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage.
  19. Firmly hand tighten the clamping screw (2) against the dies.
    20. Fig 6: Rotating J 45405 To Bottom Against Die Cage
    GM900944Courtesy of GENERAL MOTORS CORP.
  20. Select the appropriate forming mandrel and place into the forming ram.
  21. Rotate the hydraulic fluid control valve clockwise to the closed position.
  22. Rotate the body of the J 45405  until it bottoms against the die cage. See Special Tools .
    23. Fig 7: Bottoming Forming Mandrel Against Clamping Dies Using Pipe Flaring Tool
    GM900946Courtesy of GENERAL MOTORS CORP.
  23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the J 45405  until the forming mandrel bottoms against the clamping dies. See Special Tools .
  24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract.
  25. Loosen the die clamping screw and remove the dies and pipe.
  26. If necessary, lightly tap the dies until the die halves separate.
    27. Fig 8: Inspecting Brake Pipe Flare Diameter
    GM1201233Courtesy of GENERAL MOTORS CORP.
  27. Inspect the brake pipe flare for correct shape and diameter (a).

    Specification:  7.10 mm (0.279 in) +/- 0.18 mm (0.007 in) flare diameter for 4.76 mm (3/16 in) diameter pipe

  28. If necessary, using the removed section of pipe as a template, shape the new pipe with a suitable brake pipe bending tool.
    IMPORTANT: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or vibrating components.
  29. Install the pipe to the vehicle with the appropriate brake pipe unions as required.
  30. If previously released, secure the brake pipe to the retainers.
  31. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual)  or Hydraulic Brake System Bleeding (Pressure) .
  32. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.