SG Lou

My heart fell into my stomach earlier this evening. I got called in for OT on Wed.Night, knew nothing was going on at work, so I purchased new bulbs for the front directional and marker lights. Right side bulb was burnt out. Put the car up on the lift, pulled the access panels and replaced the bulbs. Co-Worker comes out to the garage to see what i'm up to, turns on his flashlight and starts looking at the underside of the car. Next thing I hear is "Louie, come here" Directing the flashlight beam up over the differential he says, 'Look at those rusted lines" What Lines Jerry ?
"Brake line you moron" So i look at what he's talking about. Where the 2 lines, coming from the ABS unit to the rear, that are threaded together above the Differential are all rusted away. I mean, the right side line is less then 1/2 the diameter of the left one. Panic set in . At first I thought, ok, I can replace the lines from the connections , back. Then I look closer, the other side is just as rusted away. SO now I'm looking at replacing all of the lines, from the ABS unit right back to the calipers on both sides.
If it was just the 2 lines from the fittings back, it would be pretty easy.
But damn......those lines are really tucked up there along side the torque tube. Not to mention what a nightmare it will be to disconnect them from the ABS unit and remove them all the way back !

Has anyone ever had to do this before? I haven't even begun to look online and see if I can get new lines.

One thing I did think about was, being the accessibility is easy I can cut the lines back past the rust, get new fitting and re-flare the ends so I don't have to mess with trying to remove the lines all the way back to the ABS unit .
Good Idea or no ?

Added note : I AM NOT GOING TO SPLICE ANYTHING...It was just a thought !

mrlmd

Cutting and splicing brake lines together is illegal in some states and many mechanics and brake shops won't do it, for safety reasons. Better to replace the entire line.

SG Lou

Been doing some research and reading since I posted this. Seems like our brake lines don't have the standard flare on the ends but something called a bubble flare that's almost impossible to do with a run of the mill flare tool kit.
Looks like it's going to have to go into a shop and have them replaced.
NOT A HAPPY CAMPER at the moment !

duramaxsky

This is a problem on GM trucks as well. They use cheap steel lines. There are companys that make SS replacement kits for the trucks. They cost less than the junk from GM. Maybe they make them for C5s. There may be a recall on the trucks as there have been many wrecks because of them. Most Vettes don't go out in the rain so not as big a problem.

SG Lou

Oh don't i know it ! Just a few months ago I replaced ALL of my hard lines on my 03 Silverado because one of them blew out on me on my way home from work.
I went with a SS Pre Bent Kit and all is well.

I looked for a few of those places online....no one makes replacement lines for a C5....Just C4 and older !

66BBDriver

I ended up Changing all the brake lines on my 2001 2500HD truck in the past year. They were rusted to the point of failure. I replaced them with S/S lines from Inline Tube, this is a very good group to work with.
Looks like I had better be taking a good look at the '01 Z06
Tommy

66BBDriver

I just checked the Inline Tube site and Lou is correct, only up to C-4.
Tommy

duramaxsky

Mine look OK on my 03 Silverado. There is a recall attempt underway right now. I they are not recalled I will change mine just to be safe. My luck the pedal will go to the floor when pulling a heavy load and no room to stop.

duramaxsky

So few C5s or C6s are ever in the rain. No demand yet. The C5s are getting cheap enough to become DDs. Then there will be demand.

JR-01

C5s don't have stainless steel brake lines? I figured a 50,000 dollar car would.

duramaxsky

At the end of the day they are just a Chevy. That's why its funny to see them compared to world class super cars. They are not in the same leauge. But they don't cost as much either. But you can not expect anymore than normal Chevy quailty.

kirt70camaro

Inline would probably make them if someone sent them an original. They just did a fuel line for my friend. Hew needed one for a 66 396 impala with the factory holley. he took the old one to them and they made it for him.

SG Lou

I wish I had a place like that close to where I live. I'm NOT going to a Stealership. I can see the Invoice now : $200-parts, $800-Labor

JR-01

Never thought of them as a super car, but they are an expensive two seater. Stainless lines are not that much more expensive and should have been standard on a C5 IMO. I wonder if C7s have stainless lines.

Joe_A

You can fit and bend all the lines and bring the lines to a Hydualic hose place they can do the bubble flare for you.
Amazon also has a bubble flare tool kit for $30 buy it, use it, and sell it when done

duramaxsky

Fleabay has them for $20.

Lee DeRaud

And millions of cars with brake lines of the same material are constantly driven wet.
I'm wondering if the problem is more one of humid storage conditions on rarely-driven cars, especially in road-salt states.

WetteVette

Thanks for the heads up. I'll have mine checked the next time the car is up on the rack.

tommyo4

I was in the same position as you about 6-8 months ago. My rear passenger side line rusted and had a hair line crack on the bend. I went to a dozen shops and all wanted a ton of money tondo the lines and some shops said no because of the tight spaces. NOONE MAKES STOCK fitment replacements.

After talking to shops and doing some research I went to napa auto store and bought two lines that were bubble flares and two adapters for then I cut them down to fit correctly. To be honest, it wasn't a bad job. I'm not a mechanic either.

Take off the lines and take them to napa for the same gauge lines and couplings. The workers should be able to help you out.

The toughest part is bending them yourself to match the existing. Note: make sure you done over bend or have the lines resting on any metal or axles where it can rub and wear away the new lines.

Let me know if you have questions.

Lee DeRaud

And make sure they can't come into contact with the CV joint boots, or they will cut right through them. That repair isn't cheap either.