That said, if you're determined to do it yourself, here's a general outline. Remember, this is a simplified overview and specific steps may vary slightly depending on the exact configuration of your vehicle. Always consult a repair manual specific to your 2000 Chrysler Town & Country LXi for detailed instructions and diagrams.
1. Safety First:
* Disconnect the battery's negative terminal. This prevents accidental short circuits.
* Gather your tools: You'll need various wrenches (metric), tubing cutter, flaring tool, brake line bender, double-flared fittings, new brake lines (the correct length and type!), brake fluid, a clean container to catch the old fluid, rags, safety glasses, and gloves.
* Secure the vehicle: Use jack stands to support the vehicle safely after lifting it. Never work under a vehicle supported only by a jack.
* Consider using a helper: This job is easier with an extra set of hands.
2. Preparation:
* Locate the damaged brake line(s). Identify the section needing replacement.
* Drain some brake fluid. This reduces the amount of fluid spilled during the process. Open a bleeder valve on a caliper to release some pressure.
* Plan your routing: Carefully trace the path of the old line to determine the best way to route the new line. You want to avoid sharp bends and ensure sufficient clearance.
3. Removal of the Old Line:
* Disconnect the brake lines: Use appropriate wrenches to carefully disconnect the old brake line from its fittings. Be prepared for some brake fluid to leak. You may need to use a wrench to hold the fitting while loosening the nut.
* Remove the old line: Carefully remove the old line from its clips and brackets. Take pictures or make notes as you go to aid in re-installation.
* Clean the fittings: Thoroughly clean the brake line fittings using a wire brush and compressed air to remove any debris.
4. Installation of the New Line:
* Cut the new line to length: Measure carefully and cut the new brake line to the correct length using a tubing cutter.
* Flare the new line ends: Use a flaring tool to create the double-flared ends on the new brake line. This is critical for a proper seal.
* Bend the new line: Carefully bend the new line to match the path of the old line, using a brake line bender to avoid kinks.
* Connect the new line: Attach the new brake line to the fittings. Tighten the connections securely, but avoid over-tightening.
* Secure the new line: Attach the new brake line to the clips and brackets using the same routing as the old line.
5. Bleeding the Brakes:
* Reconnect the battery.
* Fill the master cylinder with brake fluid.
* Bleed the brakes: This is crucial to remove air from the brake lines. Follow the proper bleeding procedure (usually starting at the furthest wheel from the master cylinder and working your way closer). You'll need a helper to pump the brake pedal while you open and close the bleeder valves.
6. Testing:
* Test the brakes: After bleeding, carefully test the brakes in a safe, controlled environment. Make sure they feel firm and responsive. If there's any softness or sponginess, there might be air still in the system or a leak. Repeat bleeding if necessary.
* Inspect for leaks: Thoroughly check all connections for leaks.
Disclaimer: This information is for general guidance only. The actual process may vary and is dependent on your specific vehicle. Improper brake repair can lead to serious injury or death. If you are not comfortable performing this repair, consult a qualified mechanic. Always refer to a repair manual specific to your vehicle for detailed instructions.
