Here's a general outline of the process. This is NOT a comprehensive guide and should not be considered a substitute for a proper repair manual specific to your 1992 Chevy S-10. Consult a repair manual for detailed instructions, torque specifications, and diagrams specific to your vehicle's year and model.
1. Preparation:
* Safety First: Wear safety glasses and gloves. Use jack stands to safely lift the truck. Never work under a vehicle supported only by a jack.
* Gather Tools: You'll need various wrenches (metric), a tubing cutter, a flaring tool (double flaring is recommended for brake lines), brake line bender, a flare nut wrench, a pipe wrench (for stubborn connections), a new brake line (get the correct length and diameter from a parts store – bring a sample of the old line if possible), brake fluid, and rags.
* Drain Brake Fluid: Open the bleeder valves at each rear wheel to relieve pressure in the system before disconnecting any lines. Collect the fluid in a container.
* Locate the Line: Trace the rear brake lines from the rear axle back to where they connect to the main brake line under the vehicle. This is often near the frame rail.
2. Removal of the Old Brake Line:
* Disconnect the Line: Carefully loosen and remove the connections at both ends of the section you're replacing. Use the correct wrenches and be prepared for potential resistance. The connections might be flare nuts. Use a flare nut wrench to avoid rounding off the nuts.
* Remove the Old Line: Carefully remove the old brake line from its mounting points and routing. Take note of how it's routed to ensure you replicate it correctly when installing the new line. Take pictures if it helps.
3. Installation of the New Brake Line:
* Measure and Cut: Measure the length of the new brake line needed, adding a little extra for bends. Use a tubing cutter to cut the line cleanly and squarely.
* Flare the Ends: Use a double flaring tool to create the correct flare on both ends of the new line. A poorly flared end will leak. Practice on scrap tubing if you're unfamiliar with the tool.
* Bend the New Line: Carefully bend the new line to match the routing of the old one. Use a brake line bender to create smooth, consistent bends. Avoid sharp kinks.
* Connect the New Line: Connect the new brake line to the fittings at both ends, tightening them securely with the appropriate wrenches. Be careful not to overtighten, which can damage the fittings.
4. Bleed the Brakes:
* Reconnect Everything: After installing the new brake line, ensure all connections are tight and secure.
* Bleed the Brakes: You *must* bleed the brakes to remove air that entered the system during the repair. This is crucial for proper braking function. Use a brake bleeder kit and follow the proper bleeding procedure (usually starting with the furthest wheel from the master cylinder). Have a helper pump the brake pedal while you open and close the bleeder valves.
5. Final Checks:
* Inspect for Leaks: Carefully inspect all connections for leaks. If you find any leaks, tighten the connections or replace any damaged parts.
* Test the Brakes: Before driving the vehicle, thoroughly test the brakes to ensure they function properly.
Disclaimer: This is a general guide, and the exact procedure might vary slightly depending on your specific S-10 model. Always consult a repair manual specific to your vehicle for accurate instructions and torque specifications. Improper brake repair can be dangerous. If you are unsure about any step, seek professional help.
