brake light just appeared while on vacation

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Hello, folks...

The family and I are on vacation 12 hours from home in Cape Cod. The evening we arrived, my wife noticed the brake light was on. I checked the brake fluid reservoir and found the fluid to be at the "minimum" line (it was checked and at "maximum" before leaving), and a ~6" puddle of fluid under the van (the van had been parked for some hours before I got around to checking).

The van is a 1993 Mercury Villager.

I took the van to a local Meineke; the only place able to see me on short notice, and the gentleman there eventually found the leak, which appears to be just after the master cylinder. He was very hesitant to replace just a portion of the line as the whole shootin' match was rusted badly: In fact, the proportioning assembly near the rear of the vehicle was rusted and seized. He felt that buggering with one part of the line would jeopardize the other parts of the system, and suggested that the entire system be replaced.

My decision at this point is between two options:

1) Write off another day and ~$450 to get the line replaced.

2) Replace the fluid daily (I am losing, depending on usage, about one full reservoir of fluid per day. The reservoir is rather small..) and drive carefully: Downshifting and walking!

My question for you is this, then: If the leak is new, and if we drive very little while here and treat the brakes with kid gloves, and keep a sharp and vigilant eye on the fluid level, is it safe to "ride this out" until I get home? After I get home, I figured I would curl up under a warm pile of blankets until the situation resolved itself.
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We won't be taking the van out, save for a couple of ~2 or 3 mile trips to a ferry here and a beach there, by the way. The trip home is almost exclusively on I-90/ 403/ 401 in NY and Ontario.

Thanks for your feedback!
 
Of course how much risk you're willing to take is your business, but I wouldn't say by any stretch that it's "safe" like this. Even if you are gentle with your brakes, what would happen if you had to panic brake on the freeway for any reason? Based on how the rust looks is it possible that something could blow out and you'd lose all pressure very quickly?
 
Replacing a brake line is not 450 dollars.

Take it someplace else.

Honestly, not to be a jerk or anything, but I wouldn't take a 1993 anything anywhere outside of my local area.

Heck, I don't even take my 2003 car on road trips when rental cars are so cheap, and when they break in the middle of nowhere, you call the rental car company up and yell.
 
Originally Posted By: JustinH
Replacing a brake line is not 450 dollars.

Take it someplace else.

Honestly, not to be a jerk or anything, but I wouldn't take a 1993 anything anywhere outside of my local area.

Heck, I don't even take my 2003 car on road trips when rental cars are so cheap, and when they break in the middle of nowhere, you call the rental car company up and yell.


JustinH -

re: The $450 price tag - - I probably underinformed you - The $450 was for the replacement of the brake line, the master cylinder and the proportioning valve... Basically everything the resident expert there thought was in the late late winter of its life.

re: The age of the van, nary a blip blipped on the JERKDAR; no offense taken. My wife and I read your reply and both thought the rental concept was terrific. The van runs very, very well, by the way. It was immaculately taken care of for its entire life, and it honestly never crossed my mind that it may show its age during the trip.

Another idea came to mind as we read your reply. If we just found a rental place that had a two-tone 1993 Mercury Villager...
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It's safer to bite the bullet and have it done. It's likely at a discount over Canadian prices for the same job. Probably $200 in parts and 2 hours labor at $90/hour. Plus taxes.

On the other hand, it's your car, and your call.
 
One of the advantages of wrenching in the south! The one or two yankie rustbuckets I've attempted rusted brake line replacement on were some of the biggest P.I.A. I've ever gotten involved with. Once one section is replaced another busts.

Bob
 
When my older wrench buddy services a not too old vehicle, he often remarks that he'd really rather not see it again when the hard lines fail.

He doesn't "mend" them either. It's just a matter of which corroded section let go first.

I don't know how the OEM's selected jeeeest the right alloy to pass some SAE standard, yet decay from environmental factors with such success.
 
You are lucky. I have seen eight year old vehicles with lines that won't pass inspection due to rust. The rest of the car and undercarriage still looks perfect.

Sometimes they loop down through a zone that gets sandblasted like a wheel well and the rest is so akward to get at, protected, and perfect, it makes sense to cut, flare, and splice.

OTOH it gets to be one of those jobs where the rubber hoses rust to the lines so you get do to the whole thing from the MC to the wheel cylinders, and no mechanic would want to estimate anything less until he tears into it.

As jobs go I bet you could find someone to do it for $200, "ernie" at the corner gas station could pull it off.
 
It's discussions like this that make me glad I don't live in a rust-prone area :) I went in plenty of 400 mile round trips in my 83 280ZX and the gf has taken her 93 Volvo on 700 mile round trips up north plenty of times without any concern.
 
Argh! I frickin' hate salt!

I wonder what it would be like to wrench in the south, 20 year old beaters still relatively fresh underneath.

Here in MN, the oxyacetylene torch gets used often!

But yeah, brake lines stink to replace. So many little turns and tight spaces, its a major PITA.

Personally, I wouldn't feel safe driving a car with leaky brake lines anywhere, let alone back home from a vacation!

I'm not a gambling man when it comes to safety, if it's a major safety component (which it is) it needs to be replaced ASAP.
 
Originally Posted By: AcuraTech
Argh! I frickin' hate salt!

I wonder what it would be like to wrench in the south, 20 year old beaters still relatively fresh underneath.

Here in MN, the oxyacetylene torch gets used often!



The blue wrench.
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Thanks for all of the advice. We've luckily been able to patch together a heck of a dance card for the rest of our stay here that is within walking distance or a short cab ride.

I have an appointment with the local service center (suggested to us by everyone we've asked) for Friday, where I HOPE we'll be able to get this all fixed up without creating more problems.

Thanks again, folks -- Brake line issues and their severity are beyond my level of automotive acuity, and I may very well have made an irresponsible decision were it not for your feedback.

oilyriser -- Even if the brake lines get patched up; or in the worst case we have to rent a car to get home and leave the van here or drive in into the bay, I will still let you know when we're heading for home so you can remain indoors. After all, the odds are that my wife will be taking a driving shift by the time we re-enter Canada.
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