Front brake flexi hose problem

[roymck]

On day 2 of lockdown thought I would do my S disc brake conversion . All was going well until I tried to replace the perished rubber flexi hose with a stainless braided replacement . Problem is I cannot get at the flexi hose locknut under the clutch housing . The end of the flexi pipe goes through the subframe into a locknut and then into a 4 way tee fitting .

Thoughts are cut the metal end of the flexi off flush with the bottom of the subframe , then lift the Tee up into the engine compartment and hopefully unscrew what left of the fitting out and then feed the new hose up into the tee again .

Any thoughts on this , have you had this problem .

[GraemeC]

Ideally you'll need to unscrew the 4 way first (4 sounds like a lot of 'ways') and get it out of the way - pun not intended! Then you should be able to get a socket on a long extension down there (off hand I think it is either 15/16" or 1" A/F). Plenty of penetrating spray and a pair of vice-grips on the hose side of the fitting and you should be away.

This will also allow you to replace/re-anneal the 2 copper sealing washers either side of the brass fitting.

[Simon776]

4 sounds like a lot of 'ways'

It certainly does, it is normally just a two way connector down there which has a central hole for the banjo connection which holds it all together and has the brake light switch in the top.

http://www.minispares.com/catalogues/cl ... spx?1~9~78

[bwaminispeed]

Well, flex line, pressure switch, two lines, technically, it is 4 ways........

[1071bob]

My car's previous owner had a simpler approach, 'gas-axe' a hole in the inner wing to access the problem!

[roymck]

Thought of the day , support engine and remove clutch housing cover to gain more room . That might help , will it? . Haven’t even looked at radiator side yet.

['S'-type]

My take on this, (if someone hasn't previously cut a nice access hole in the inner wing!).
Pressure switch should be relatively easy to remove from the top with extension bars and deep socket. There's not much in the way on early cars.

If it's been on the car for a long time, just sacrifice the old flexi and cut off below start of metal union. This allows access for a firmly fitting ring spanner from underneath. I say firmly fitting, but I still don't know what af size it is. What I do know is a 3/8 whitworth is bang on. You can also grip the stub of the metal union with some molegrips for additional umph.

Next slide a 15/16th open ended spanner from the front (grille off) along the subframe to engage the large lock nut. You may have to swivel from underneath to get it mesh. Then apply brute force to the ring spanner from underneath with bar if necessary. The open ended spanner above should lock itself against the subframe rebate.
Failing that hacksaw flexi off flush below subframe having removed the pressure switch first. Hard to do without chewing the subframe a bit.
Hope that makes sense. It's bit easier with the lump out!

[roymck]

Much swearing and cursing it’s done , was original 63 hose by the look of things so no wonder the locknut was tight. Managed to disassemble from the top downwards mega tight but all back together .

Thanks all .