I noticed a steel line rusted out and leaking near the spare tire. I was able to remove the spare and take pics of it.

How do I get the exact replacement part (part number/ebay link) for this fix?

What size brake line is this 3/16, 3/8, 1/4? Is it easy to change for someone who only knows theory about brakes? What should I expect the labor the cost? Is there anything else that will need to be done like bleeding the brakes?




Attached pics: Imgur: The most awesome images on the Internet

 

Unfortunately, rusted brake lines are a major problem with all of the GM trucks. I, like you had the same problem and replaced all of the lines. The best method to repair the problem is to use a copper nickel line, as the lines will last a long time. You can get the line, in bulk from any auto parts store in your area, such as NAPA, Advance, O'Reilly etc. If you are not familiar with the repair, you may want to have a local auto shop replace the lines, but the job can be quite expensive, as it is very time consuming to do.

You can also order pre-bent lines from a business like classictube.com. I quickly looked this up and found a complete set for a 02 for $440 for 4wd and $469 2wd.

When you do a brake repair such as this, you should consider looking at the entire brake system. If one brake line has rusted through, you should check / replace others. In addition, you should consider replacing all of the flex lines, if they have not been done. Unfortunately, as you start to work through this problem, you will find that all of the parts you are working on are rusted together and you need to replace more than you originally thought. I expect that the brake fluid in the system is old and should also be flushed out as part of the bleeding system.

Good luck with your repair.

 

@mulmur1

Thanks for your input. I am looking to sell the rust bucket as soon as feasibly possible so the less cash I have to throw into it the better.

Any idea what size the line is or what the specific part is so I don't have to get the full brake line kit?

 

The main lines are 1/4 " and the rear line that runs along the rear axle is 3/16". If you just want to repair the problem, you can get pre-made brake repair section. You will need to cut the rusted part out with a small pipe tube cutter, install union fittings and then attach the brake line section into the repair area. Once you have the line repaired, you will have to bleed the brakes to get the air out of the system. Unfortunately, if your lines are this rusted, the brake bleeder screws may also be very rusted too. Try and get some penetrating oil on the bleeders a number of times before you start repairing the brake line, this way, when you are ready to loosen the bleeder screws, they will hopefully move. I would suggest that you take a good look at the other lines while you are working on the truck.

If you decide to repair more of the lines or have to, after getting into the job. You can also buy plain steel line or coated line. It is a little harder to work with that the copper nickel, but less expensive. You will need a brake flare kit (picture below) to make the lines. You can buy bulk line from an auto parts store. Take the brake fittings that you have from your truck with you and the auto parts store can match them.

There are lots of excellent videos on youtube that show you how to make brake lines, bleed the system and go through the entire repair procedure.

Brake Line Repair Section (You can purchase these at any local auto parts store)


Small Pipe Cutter (You can get this at any hardware store. You will normally find them in the plumbing department. The smaller cutter is easier when working on a vehicle. The larger cutter is better, if you decide to replace all of the lines, as you will be working off the vehicle when cutting. You can also use a hack saw or air cutoff tool.


Pipe Flare Kit (You can purchase this at auto parts stores, Home Depot, Lowes, etc.


Please let me know if you have any additional questions.

Good luck with your repair.

 

@mulmur1

I was able to secure all the parts cheap and currently scouting for a mechanic. Once again, thank you. It was more than I could have asked for.