Repairing brake lines — VW

Repairing brake lines
Special tools and workshop equipment required
Flanging tool for brake lines
VAS 6056
Brake filling and bleeding equipment
VAS 5234
Flanging tool for brake lines
VAS 6056
- tool overview
Flanging tool
VAS 6056/1
incl.
flanging jaws
VAS 6056/6
Pipe cutter
VAS 6056/2
Brake line scraper
VAS 6056/3
Grub screws (in shaft and at side) are adjusted and must not be readjusted!
Grip wrench with plastic jaws
VAS 6056/4
Pipe bending tool
VAS 6056/5
Screwdriver, 6 mm
angled
Flanging jaws
VAS 6056/7
Assembly overview - flanging tool
Flanging tool upper part
Unbolt to change flanging jaws
Fastening for handle
Must be unscrewed to access securing bolt for upper part.
Securing bolt
For flanging tool upper part
Grub screws for flanging jaws
For centring and holding flanging jaws
Hexagon socket head bolt, 2 mm
Flanging jaws
Various flanging jaws
Fig.
“Flanging jaw assembly instructions:”
Flanging jaw assembly instructions:
VAS 6056/6 (dark) for black brake lines
VAS 6056/7 (light) for green brake lines
Work instructions
WARNING
Never bring brake fluid into contact with fluids containing mineral oil (oil, petrol, cleaning agents), as these damage the brake system's plugs and sleeves.
Brake fluid is poisonous and must never be sucked out by mouth through a hose.
Due to its corrosive effect brake fluid must not come into contact with paintwork.
Always observe the relevant environmental regulations for disposal.
Only use new brake fluid conforming to VW standard (VW 501 14).
Note
Brake pipes may only be bent up to max. 90°. They otherwise kink or reveal deformations which impermissibly constrict the pipe cross-section.
Preferably separate brake lines at underbody.
The positions of the intermediate pieces must be selected so that they cannot chafe on moving parts.
Do not grease spindle; merely clean with methylated spirits.
Arrow on rounded side of flanging jaws must point to edge of housing. Straight side of flanging jaws must be installed to spindle, as flanging head is not otherwise formed correctly.
The
flanging tool for brake lines
VAS 6056
can be used to flange brake lines with an outer pipe diameter of 5 mm without damaging the coating. In certain cases, this allows sections of brake lines to be renewed at less expense.
The use of flanging tool V.A.G. 1356 is not permitted due to the coating and the diameter of the black brake lines.
Separating
Unbolt relevant brake line at brake caliper or wheel brake cylinder; catch escaping brake fluid and dispose of this as per regulations.
Cut through brake line at a suitable point (straight, freely accessible section) with pipe cutter
2
.
Remove section to be renewed.
Degrease brake line surface.
Clamp brake line in grip wrench
4
so that approx. 50 mm project out of plastic jaws.
Clamp scraper
3
in a drill and position on brake line.
At slow drill speed and with gentle pressure on brake line, scrape coating off brake line.
Length of scraping is determined by stop in scraper.
Remove scraper from brake line and remove scraping residues.
Remove mole grips.
Flanging
Slide union screw
D
onto brake line.
Slide brake line
B
to stop
A
in flanging tool.
Note
Brake line must be positioned against stop when the hexagon socket head bolts are tightened, or the flange will not be formed correctly.
Pre-tension brake line in flanging tool until brake line can no longer be moved. Then fold up stop
A
and use angled driver
C
to tighten hexagon socket head bolts in diagonal sequence.
Turn spindle to stop in flanging tool.
Turn spindle back again.
Release Allen head bolts diagonally.
Remove brake line from flanging tool. Clean and check brake line and flange.
Briefly flush the section of brake line remaining in the vehicle.
To do this, connect
brake filling and bleeding equipment
VAS 5234
, connect bleeder bottle hose to brake line flange, and allow
brake filling and bleeding equipment
VAS 5234
to run briefly until a little brake fluid has run through.
Connecting
Blow out new brake line to be inserted with compressed air.
Join brake lines using connector
E
.
Install brake line.
Bleed brake system
Chapter
.