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Sat Sep 17, 2011 4:53 pm

I just found out that my brand new hard brake line going from the passenger front brake to the master is leaking whenever I press the pedal down. Its leaking right from the fitting.

I know I need to replace it, but I am more concerned as to what would cause this, and how I can avoid this in the future. My thoughts are that maybe I bent the line at the fitting causing it to leak?

Sat Sep 17, 2011 6:01 pm

Was the line flared at the end? German lines? Most likely a quality issue. Go with good German lines and tighten them up, should be good....

Sun Sep 18, 2011 1:13 am

Go to the fitting, you need 11mm and a 17 or 18 mm box, back off the small nut just a tad until you see 1 drop of fluid coming out, now keep the joint even and level and tighten the small nut back good and tight but don't kill it. Now wipe off the fitting dry and keep an eye on it. Put a paper bag under it and pump the brakes and see if that did it.

Mine was leaking after I pulled and hung the backing plate while I repaired the axle. When I reassembled it, it leaked little. Seems like the hard line got twisted a little. I did what I described and it stopped leaking totally.

I hope it works for you.

Sun Sep 18, 2011 4:41 am

It is important that you installed the proper brake line into the car. The VW takes what is known as a "BUBBLE FLARE".
Here is an illustration of that they look like..

American cars take a double flare, notice how it is concave rather than convex. You cannot use a double flare on the German brake fittings.

Dave

Sun Sep 18, 2011 8:40 am

I tried the loosening, and tightening, a couple times, and it still leaked, and yes I used a bubble flared line.

Sun Sep 18, 2011 12:40 pm

Man, that sucks.
Can you get lines that are already flared from the manufacturer?

Maybe just get a new piece and bend it to fit.

Sorry.

Sun Sep 18, 2011 3:00 pm

I buy them pre made from my friendly local vw store. I'm just gonna chock it up to either a quality issue, or I man handled it. Either way I will be more careful when I install the line. Thanks for the help.

Sun Nov 13, 2011 9:02 pm

Where can one get a "bubble flare" tool?

djkeev your bottom pic looks more like a "double flare" and the top like a "single flare/bubble flare" how did you accomplish that with a double flaring tool? Mine flares the bottom out.

djkeev wrote: It is important that you installed the proper brake line into the car. The VW takes what is known as a "BUBBLE FLARE".
Here is an illustration of that they look like..

American cars take a double flare, notice how it is concave rather than convex. You cannot use a double flare on the German brake fittings.

Dave

Sun Nov 13, 2011 9:38 pm

http://www.amazon.com/OTC-4504-Stinger-Bubble-Flaring/dp/B0015PMZMU

Sun Nov 13, 2011 9:54 pm

skabonner wrote: http://www.amazon.com/OTC-4504-Stinger-Bubble-Flaring/dp/B0015PMZMU

Thanks. I found the same one on ebay. I was hoping for some feedback on one located at a local parts store. 8)

Mon Nov 14, 2011 9:49 am

KombiMonster wrote: Where can one get a "bubble flare" tool?

djkeev your bottom pic looks more like a "double flare" and the top like a "single flare/bubble flare" how did you accomplish that with a double flaring tool? Mine flares the bottom out.

djkeev wrote: It is important that you installed the proper brake line into the car. The VW takes what is known as a "BUBBLE FLARE".
Here is an illustration of that they look like..

American cars take a double flare, notice how it is concave rather than convex. You cannot use a double flare on the German brake fittings.

Dave

Yes, that's exactly what the photos are and are captioned to point that out.

I made the "fake" bubble flare by only doing the first step of making a double flare, putting the die in the end of the pipe and squeezing it down causing it to swell above the clamp. Then just stopped right there.

I must say, I wasn't convinced it was the best system and the angle of the bubble is off from the proper Bubble flare angle so I did purchase a bubble flare tool and used it to make my brake lines for my 69 Ghia. The "fake" bubble flare system I would use in a pinch if I had to but recommend the proper tools whenever possible.

In the photo, the small round black units are dies with a built in pin that slips into the pipe and causing the bulging thus creating the bubble flare. The proper bubble flare tool works in the same manner, just at the correct angles.

Dave

Thu Nov 17, 2011 11:23 pm

Dave,

I'm familiar with a double flare tool kit. I can see your tool that holds the line in place has a 45 degree faced edge. That won't keep/make the 90 degree required for a bubble flare. Did you use the back side of the clamp?

Sat Nov 19, 2011 7:47 am

KombiMonster wrote: Did you use the back side of the clamp?
yes,you use rear as it don't have the champher

Sat Nov 19, 2011 9:28 am

Making a bubble flare by only doing the first half can work sometimes, but it's not right. The back sode of the DIN bubble flare is flat, where the back side of the first half is tapered.

All of your sealing takes place at the flare. If you have a leak, either the flare isn't seating properly to make a seal, or you have a split in the flare. A quick test it to clean the flared end, and color it with a Sharpy. Install the end in the port barely hand tight and spin it. Remove it and you can see where it's hitting......or not hitting. It should be hitting in the middle of the flare, from top to bottom. If it's not, the flare angle is off and can potentially leak. Good luck!