Here's a general procedure. Specifics may vary slightly depending on the year and model of your B2500:
Tools you'll need:
* Wrench: The correct size to fit your brake line nuts. Usually a combination wrench or open-end wrench will work best.
* New copper washers: Get the correct size for your brake lines. Don't reuse old ones.
* Clean rags or shop towels: To clean up spilled brake fluid.
* Brake fluid: You might need to top off the master cylinder after you're done.
* Container to catch spilled fluid: Brake fluid is corrosive, so don't let it get everywhere.
* Penetrating oil (optional): May help loosen stubborn nuts.
Procedure:
1. Safety First: Engage the parking brake firmly. This is critical.
2. Locate the Leaking Connection: Identify the brake line connection where the copper washer is leaking. It will likely be wet with brake fluid.
3. Protect your Paint: Put rags or paper towels down to protect the paint around the area you're working on.
4. Clean the Area: Thoroughly clean the area around the connection with a rag and brake cleaner (if available). This will help you see what you're doing and prevent contamination.
5. Loosen the Nut: Carefully loosen the brake line nut using the appropriate wrench. Apply penetrating oil if the nut is stuck. Work slowly and carefully to avoid damaging the brake lines.
6. Remove the Old Washer: Once the nut is loosened, carefully remove it and the old copper washer. Inspect the mating surfaces of the fitting and the line for damage. If there is significant damage, replacement parts may be required.
7. Install the New Washer: Place the new copper washer onto the brake line fitting. Make sure it's seated correctly.
8. Tighten the Nut: Carefully tighten the nut by hand, then use the wrench to tighten it to the manufacturer's specified torque. Do not overtighten. Overtightening can damage the fitting or brake line.
9. Check for Leaks: Carefully inspect the connection for leaks. You may need to gently tighten the nut a little more if you see any leaks, but don't overtighten.
10. Repeat as Necessary: Repeat steps 5-9 for any other leaking connections.
11. Check Brake Fluid Level: After completing all repairs, check the brake fluid level in the master cylinder and top off if necessary.
12. Test the Brakes: Pump the brake pedal several times to build pressure. Then, carefully test the brakes to ensure they are functioning correctly. If you notice any spongy feeling or reduced braking power, you have a problem and need professional help immediately.
Important Notes:
* Brake fluid is corrosive and harmful to paint and skin. Wear gloves and eye protection. Clean up any spills immediately.
* Do not use Teflon tape or any other sealant on brake lines. Copper washers are designed for this purpose.
* If you are unsure about any part of this procedure, consult a qualified mechanic. Improperly repaired brakes can lead to serious injury or death.
This is a general guide. Always consult your vehicle's repair manual for specific instructions and torque specifications. Again, if you're not comfortable working on your brakes, have a qualified mechanic perform this repair.
