Forum Discussion

Katman1100's avatar
Katman1100
Explorer
Dec 03, 2017

Front axle swap 97 E superduty brake line issue

I have just completed the swap of the front axle on my 97 Born Free to the new heavier axle from the 2010+ era chassis. I have run into one issue and that is I need a different brake line for the left/drivers side. I was given part numbers by JD a member here who has also completed this task and provided lots of insight to this task.

The part numbers I have are Dorman H620985 Right and -86 Left. These have been confirmed to be correct for the newer axle. The right side worked great, the problem is the left side has a different fitting at the chassis end. I believe this is because the 97 chassis does not have front anti lock brakes, I am not positive on this.

Has anyone else done this swap on an early chassis like the 97, and if so what brake line did you use on the drivers side? My current line though not the ideal shape would work if it was about an inch longer! I am trying to find an aftermarket one for the earlier chassis that may be slightly longer that what I have. Does anyone have any ideas?

I will post a thread up in the future to hopefully help others who may decide to do this swap in the future or answer any questions.
Class C
  • Katman1100's avatar
    Katman1100
    Explorer
    Dec 12, 2017
    OP here. Just wanted to follow up and let everyone know I did have to get a custom brake line which involved quite a bit of hassle, but was possible! I can definitely tell with the new axle that it brakes much better.

    Overall I think the swap was well worth the time and effort to change. I will be doing a roadtrip here over the holidays which will involve about 4000 miles or so, so that should give it a good test.

    I also had the alignment done and was able to get the caster set to 5.7 on left and 6.3 on the right and I can tell the steering has much less wondering in the short time I have driven it. Of course I have a new axle with everything tight so I am sure that helps too. I will start a thread later with more about the alignment later.
  • Katman1100's avatar
    Katman1100
    Explorer
    Dec 03, 2017
    Thanks for the help and confirmation that it is the anti lock brake giving me the issue. I believe even the e 350 vans of that year had anti lock as well. Mine must be one of the last years without anti lock on the front.
    Just to clarify mine is a 97 e superduty which is what was later called the e450.
    As far as swiching out the steel lines that maybe a possibility but I would still need the right fitting where the steel connect's to the flexibile hydraulic line. My steel lines look like they are in great shape as well.
    Tomorrow I am going to take my parts and see if I can have a custom one made. I don't think it will be to big of deal,hopefully! I will let you know what I find out.
  • SidecarFlip's avatar
    SidecarFlip
    Explorer III
    Dec 03, 2017
    Maybe I'm out in left field on this but I'd run new lines (Ni-Cop) and be done with it. One nice thing about earlier systems is no fancy flares, just standard double flares and flaring tools (I have a Rigid double flaring tool) aren't all that expensive either.

    Learned the hard way with my 97 about OEM steel lines and what happens to them as they age, they corrode. Not an issue with Ni-Cop and Ni-Cop is easy to work with too. Comes in a roll so you just unroll it and bend (by hand) to fit. I did my entire brake system from master cylinder to all the wheels in a weekend.

    Best part is, I'll never have to do it again. Ni-Cop is forever.
  • j-d's avatar
    j-d
    Explorer II
    Dec 03, 2017
    I think this swap might be into the earliest chassis so far. "It fits" but takes a little more adapting.
  • carringb's avatar
    carringb
    Explorer
    Dec 03, 2017
    j-d wrote:

    Hope someone who's done an earlier model already figured it out. CarringB did his 2000 E350.


    Sorry I can't help on this one. They worked on mine, but mine is 4-wheel ABS. I the OP is tight that the ABS difference is what's causing the misfit.
  • SidecarFlip's avatar
    SidecarFlip
    Explorer III
    Dec 03, 2017
    My 1997 F350 pickup has antilock brakes, a tone ring built onto the hubs actually.

    Best thing I did last summer was reline all the brake lines with Ni-Cop brake lines and get rid of the corrosion prone steel ones. 1997 lines are standard double flare fittings btw.
  • Katman1100's avatar
    Katman1100
    Explorer
    Dec 03, 2017
    Hey JD once again thanks for your help. I actually found a couple places that can make me what I need hopefully, but will probably have to wait until Monday when they habe someone to do it. I was just hoping to complete everything today.
  • j-d's avatar
    j-d
    Explorer II
    Dec 03, 2017
    There ARE places that make custom hoses. Masthead is a mobile version of that. Some NAPA shops might. You could have 1997 on the chassis end and 2017 on the caliper end. Remember the fittings on the ends are "clocked" so the hose installs and rests without a twist in it. Also, the E450 uses HydroBoost braking vs. vacuum boost on E350. I wondered why and found out that Hydro produces Many Times the brake apply pressure that Vac can supply. Multiple times more, so even more reason to make sure brake hoses are RIGHT.
  • j-d's avatar
    j-d
    Explorer II
    Dec 03, 2017
    newman fulltimer wrote:
    if the 85 worked why not use another on the other side?

    The brake hoses have a very different Left vs Right configuration.

    @OP... I replaced 2002 with 2012, I ordered hoses for 2012 and they fell right in place.

    I can think of a few fixes...

    Adapter Fitting. A place like NAPA has a collection of brass fittings. Bring Old and New, see if they offer a match up.

    Replace the hard line on the chassis. That comes with the risk you can't match the other end.

    Be sure anything you do stays out of the way of the tire.

    Hope someone who's done an earlier model already figured it out. CarringB did his 2000 E350.

    Post pictures. Maybe it'll trigger an idea from someone.
  • Katman1100's avatar
    Katman1100
    Explorer
    Dec 03, 2017
    It has the wrong fitting on top. On my 97 chassis the left side goes through the frame and has a clip to hold it in. Then 2 break lines connect instead of just 1.

About Motorhome Group

38,708 PostsLatest Activity: Mar 05, 2025