2002 SR5 Front Brake line/pipe and hose replacement

2002 with 310,000k. Rusty.
The truck requires new Rotors, pads, and calipers (frozen).

The brake pipe/line from caliper to flexible hose was rusty and weak. It sheared/torqued when attempting to remove nut from current caliper.

Next step was to isolate and replace this pipe, but the connection to the rubber line is also rusty and not budging.

The next logical step is to move up the line and disconnect top end of the rubber line from the next pipe connection in the upper wheel well. This would isolate part replacement to two pieces - the rubber section and the pipe to the caliper...I have not tried this yet.

My concern is this: I will further damage as I move up the brake line chain, ultimately having to replace the all the lines from the caliper to the master cylinder. I am not opposed to doing this given the rust and age of the vehicle. It is the right thing to do from a safety

I cannot locate any videos that provide instruction on this task.

• How difficult is the job?
• Can I "bend my own" lines? They have long pipe (straight) at the auto parts store.
• What technique is used to bend them?
  • A spring similar to bending copper lines to avoid crimping? I would simply need to flange the ends and get the right nuts/couplers.
• Is it one line from the master cylinder to the upper wheel well?

I noticed that each line running from the master cylinder has a series of "coils", about 5-6 high. Are these still needed?

I appreciate the guidance, insight, and any support links that are provided.
Found this on bending lines: How To Bend and Flare Brake Lines EASY

Scotty C.

 

The coils are for cooling. Needed for safety.

 

Due to the length of pipe running from the master cylinder to each of the front calipers, all the bends, and weaving through a few components in the engine bay, is it acceptable to do an installation with multiple sections of pipe?

Can I replicate the coils with a pipe bender?

 

People have spliced brake line sections since forever. Just don't use compression fittings or single flares.

You should be able to get something close to the coils with a pipe bender, but I'd probably just splice the current ones into your new line if they aren't rusty.

 

From Microsoft Copilot

For a 2002 Toyota 4Runner, here are the key specifications for brake pipes and fittings:

Brake Pipe Size

• The hard brake lines are typically 3/16" (4.75 mm) in diameter.
• This size is standard for many Japanese vehicles and is often labeled as "Japanese line" at auto parts stores.

Fitting Specifications

• The fittings are generally M10 x 1.0 metric thread.
• Toyota uses double flares (inverted flares) on their brake lines, which are essential for proper sealing.
• You’ll need a flare nut wrench (10mm and 14mm sizes) to avoid stripping the fittings during installation.

️ DIY Considerations

• You can bend your own lines using a tube bender to avoid crimping.
• A double flaring tool is required to prepare the ends of the brake lines correctly.
• Pre-cut and pre-flared lines with fittings are available at most auto parts stores if you prefer not to fabricate them yourself.

Would you like help finding a brake line kit or tools for this job?


References
[1] [2] What Size Are Toyota Brake Lines? - GearShifters