However, if you're determined to do it yourself, understand this is a potentially risky undertaking. Here's a general overview; this is not a comprehensive guide and should not be considered a substitute for a professional repair manual specific to your Expedition's year and model.
1. Safety First:
* Disconnect the battery negative terminal. This prevents accidental shorts and activation of the brake system.
* Use safety glasses and gloves. Brake fluid is corrosive.
* Work in a well-ventilated area. Brake fluid fumes are harmful.
* Obtain a professional-grade brake line flaring tool. Improperly flared lines will leak and lead to brake failure.
* Have a helper. This job is much easier with an extra set of hands.
2. Preparation:
* Consult a repair manual specific to your Ford Expedition's year and model. This manual will provide detailed diagrams, torque specifications, and procedures.
* Identify the damaged brake line section. Note its location and routing.
* Gather necessary materials: New brake line of the correct length and diameter, brake fluid, flaring tool, tubing cutter, wrenches (various sizes), double-flare nut, appropriate fittings (if needed), rags, and a container to catch old brake fluid.
3. Procedure (General Steps):
* Drain brake fluid. This is crucial to reduce the risk of air entering the system during the repair.
* Locate and disconnect the damaged brake line. This often involves disconnecting brake lines from calipers, ABS components, or other parts of the braking system.
* Carefully remove the old brake line. Be cautious not to damage surrounding components.
* Measure and cut the new brake line. Ensure you have enough length to account for bends and routing.
* Flare the ends of the new brake line using your flaring tool. Follow the instructions that came with your flaring tool carefully; improperly flared lines will leak.
* Install the new brake line. Follow the original routing carefully. Use clamps to secure the line where necessary.
* Connect the new brake line to the components. Tighten fittings to the manufacturer's specifications (consult your repair manual).
* Bleed the brake system. This removes any air introduced during the repair. This process requires a helper and usually involves opening bleeder valves at each wheel while someone pumps the brake pedal.
* Check for leaks. Inspect all connections and the brake lines for any leaks.
* Test the brakes. Test the brakes thoroughly in a safe, controlled environment before driving the vehicle.
4. Important Considerations:
* ABS System: If the damaged line is part of the ABS system, the repair is even more complex and might require specialized tools and knowledge. This is best left to a professional.
* Corrosion: Rust and corrosion can make removing old brake lines incredibly difficult. Use penetrating oil to help loosen rusted connections.
* Routing: Pay close attention to the original routing of the brake lines. Incorrect routing can lead to premature failure or interference with other components.
* Professional Help: Again, I cannot stress enough the importance of seeking professional help for this repair if you are not experienced in automotive brake system repair. Improperly repaired brake lines are incredibly dangerous.
This is a simplified overview, and the actual steps will vary greatly depending on your Expedition's year, model, and the specific brake line that needs replacement. Always consult a repair manual specific to your vehicle and seek professional help if you are not comfortable performing this repair. Brake system failure can lead to serious injury or death.
