2002 Chevy Tracker full brake system replacement

Joined
Nov 30, 2009
Messages
2,475
Location
Warner Robins, GA
Bought this little tracker for a woods toy a couple a years ago only to realize it was way rustier than I initially thought. Post from when I got it is here:


It finally popped a brake line and I decided to make a learning experience out of it since I'd never had to make my own brake lines before. Thanks to Amazon and Rockauto I got everything for the brake system for around $350. Nickle Copper brake lines, wheel cylinders, drums, shoes, drum hardware, calipers, rotors, pads, new soft lines and a new master cylinder. Everything except the metal lines under the hood and the load sensing proportioning valve in the rear. I also made a new metal fuel pressure line and replaced the severely rusted fuel filter.

It was time consuming, but I am definitely a lot more confident making brake lines now. The line I got was easy to bend by hand and didn't kink. Probably overkill for something that is only going to be on the road occasionally going forward (going to the deer camp to live), but I feel good about it. Only had about a foot left of a 25ft coil of brake line.

It also got a 95 amp alternator from a XL-7 (stock was 70 amp for tracker) and a set of NGK platinum plugs. Was surprised to see it had NGK iridium's in it, but they looked like they had 100k on them to me so I swapped them. More evidence that the first owner of this thing took care of it.
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Great job! I started using the ni-copp brake line a few years ago and will never look back. Once you have a nice cutter and flaring tool it's all pretty simple to work with. I also add stainless sheathing (cheap on Amazon for 25-foot roll) to my brake lines before flaring...if there's any abrasion risk to the line(s).

It all looks wonderful.
 
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