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Discussion Starter · #1 ·
I have a 2008 mule and the metal brake line that runs under the seats rusted through. Is it possible to repair or does that need replaced. I’m also having trouble finding a replacement if that’s the route I need to go. Thanks in advance
 

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No direct experience with that particular brake line, but...
I once owned a Suburban that had GM's diesel engine in it. Had an injector line break, and 'patched' it using a brass compression coupler. Worked until I sold the truck. Injection pressure on those old engines was at least 5, maybe 10 times as high as brake line pressure. You should be able to cut out the bad section, flare the cut ends, and install a section of same size tubing using a couple of flare unions. You might even be able to get away with compression fittings. You'd need to provide plenty of support, so the extra weight of the fittings won't cause fatigue failures from vibration.
Having said that, if it rusted through at that location (not worn through from rubbing on something), then it might happen again somewhere else in a month, or a week.
 

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If you carefully remove the entire line, you could take it to a shop that repairs brakes and ask them to use the old line as a pattern to make you a brand new line. If they won't do it, try a hydraulics shop.

If that is not possible then rv7charlie's fix might get you a few more years before the line lets go somewhere else, but of course when it comes to brakes, I would personally replace it with 100% new.

Murphy's Law dictates that the brake line will blow when you need it the most.
 

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Discussion Starter · #4 ·
If you carefully remove the entire line, you could take it to a shop that repairs brakes and ask them to use the old line as a pattern to make you a brand new line. If they won't do it, try a hydraulics shop.

If that is not possible then rv7charlie's fix might get you a few more years before the line lets go somewhere else, but of course when it comes to brakes, I would personally replace it with 100% new.

Murphy's Law dictates that the brake line will blow when you need it the most.
I was able to get the same size and fitting line from auto one and just replaced the entire line. Thanks for the suggestions
 

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Discussion Starter · #6 ·
Thanks for circling back to the forums to let us know how you made out. Glad to hear of your success. Was it mostly a straight line or were there any tricky bends?
It’s roughly 80in long and autozone only had two 40s so I needed a connector which added an inch or so which gave me a little slack which I bent to use up. It’s completely straight though until it bends up behind the pedals and then a few more bends to get it to the master cylinder. Pretty easy job though aside from all the screws that need removed to get the center panels out of the floor, which meant removing all the plastic trim pieces under the seats
 
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