However, if you're determined to do it yourself, here's a general outline. This is NOT a complete, step-by-step guide, and you should consult a repair manual specific to your 1996 Ford Econoline E-150 for detailed instructions and diagrams:
1. Preparation:
* Safety First: Disconnect the negative battery cable. Wear safety glasses and gloves. Work in a well-ventilated area.
* Gather Tools and Materials: You'll need a complete set of metric wrenches and sockets, tubing cutters, a double-flare tool (critical for proper connections), brake line bender (optional but helpful), new brake lines (exact replacements are recommended), brake fluid, a flaring nut, pipe wrenches, a wire brush, and possibly a spring compressor (depending on your caliper design). Consult your repair manual for specific sizes and types of lines.
* Obtain a Repair Manual: A Haynes or Chilton manual for your specific vehicle year and model is invaluable. It will provide detailed diagrams and procedures.
* Raise and Secure the Vehicle: Safely raise the van using jack stands. Never work under a vehicle supported only by a jack.
2. Removal of Old Brake Lines:
* Locate and Identify Lines: Carefully trace each brake line from the master cylinder to each wheel. Take pictures or make detailed notes.
* Drain Brake Fluid: Before disconnecting any lines, fully drain the brake fluid reservoir.
* Disconnect Lines: Carefully disconnect the brake lines at each connection point. Use the appropriate wrenches to loosen and remove fittings. You might need to use penetrating oil to loosen rusted or seized fittings. Be prepared for brake fluid to spill.
* Remove Old Lines: Carefully remove the old brake lines. You may need to cut sections to get them out.
3. Installation of New Brake Lines:
* Measure and Cut: Measure the new brake lines carefully to match the old ones. Use a tubing cutter to cut the lines to the precise lengths you need. Avoid kinking the lines.
* Flare the Ends: Use a double-flare tool to create the proper flare at each end of the new brake lines. This is critical for a proper seal. Practice on some scrap tubing before working on the actual lines.
* Bend the Lines (If Necessary): If you need to bend the lines, use a brake line bender to create smooth, even bends. Avoid sharp bends that can restrict fluid flow.
* Install New Lines: Carefully route the new brake lines, following the path of the old lines. Secure them with appropriate clips and brackets.
* Connect New Lines: Connect the new brake lines to the master cylinder and calipers using the flaring nuts. Tighten the fittings securely, but avoid over-tightening.
4. Bleeding the Brakes:
* Refill Brake Fluid Reservoir: After installing the new lines, refill the brake fluid reservoir.
* Bleed the Brakes: Carefully bleed the brakes at each wheel to remove any air that might have entered the system during the repair. Use a brake bleeder and a helper to pump the brake pedal. Follow the procedure outlined in your repair manual.
5. Final Checks:
* Check for Leaks: Inspect all connections for leaks.
* Test the Brakes: Test the brakes thoroughly in a safe, controlled environment. If the brakes feel spongy or unresponsive, there's likely still air in the system, or another problem.
Disclaimer: This information is for general guidance only. Replacing brake lines is a complex and potentially dangerous task. Improperly installed brake lines can lead to brake failure, resulting in serious injury or death. If you lack experience in automotive repair, please take your vehicle to a qualified professional. Consult a repair manual specific to your 1996 Ford Econoline E-150 before attempting this repair.
