Replacing rear brake pipes on a Nissan Almera Classic: a detailed guide with photos

Rear brake pipes Nissan Almera Classic (in bodies B10 And N16) is a critical element of the braking system, the condition of which determines not only braking efficiency, but also safety on the road. Over time, metal pipes corrode, crack, or rub against body parts, leading to brake fluid leaks and brake failure. In this article we will look at how to identify a malfunction, select quality spare parts and Replace the rear brake pipes yourself without contacting the service.

The procedure requires accuracy and basic skills in working with a car, but with the right approach it can be done in a garage. We will consider all stages: from diagnostics to bleeding the system, and also point out typical errors that lead to repeated leaks or uneven braking. We will pay special attention to the nuances of working with the brake system. Almera Classic, which are often missed in universal instructions.

Signs of faulty rear brake pipes

The first symptoms of brake line problems are often ignored until the situation becomes critical. Experienced drivers recommend checking their condition every 20–30 thousand km or when replacing pads. Here are the key signs that indicate the need for replacement:

• 🔴 Brake fluid leaks on the inside of the rear wheels or under the car from the rear axle. The liquid has a characteristic yellow tint and an oily consistency.
• 🚨 Soft brake pedal, which “fails” when pressed. This indicates that air has entered the system due to depressurization.
• 🔧 Corrosion or mechanical damage tubes Even small “pits” in the metal can lead to rupture under pressure.
• 🔄 Uneven brakingwhen one of the rear wheels locks later or weaker. This is often due to air leaks in a damaged tube.

If you notice any of these symptoms, It is strictly forbidden to operate the car — the risk of complete brake failure during emergency braking is extremely high. For an accurate diagnosis, jack up the rear Almera Classic and visually inspect the tubes along their entire length, especially at the points of attachment to the body and calipers.

⚠️ Attention! On Nissan Almera Classic with ABS, the tubes often rub against the fuel tank mounting brackets. Check their condition even if there are no obvious leaks - prevention is cheaper than repair.

Selection of spare parts: original vs analogues

When replacing brake pipes with Almera Classic the owner is faced with a choice: buy original parts from Nissan or analogues from third-party manufacturers. Original tubes (item number 40520-4M000 for left and 40521-4M000 for the right) guarantee a perfect fit and durability, but their price can reach 2–3 thousand rubles per set. Alternative options will be cheaper, but it is important not to run into a fake.

Among the proven analogues, the following stand out:

• 🔧 ATE (Germany) - high quality metal, resistant to corrosion. Articles coincide with the original ones.
• 🔧 TRW (UK) - optimal price/quality ratio, often used in services.
• 🔧 Febi Bilstein (Germany) - a budget option with good reviews, but requires checking for defects.

When purchasing, pay attention to:

1. Tube material - must be copper or steel with anti-corrosion coating.
2. Complete set — the kit must contain new fittings and o-rings.
3. Length and shape - tubes for Almera Classic have specific bends that are incompatible with other models Nissan.

Manufacturer	Article (left/right)	Price per set, rub.	Features
Nissan (original)	40520-4M000 / 40521-4M000	4500–6000	100% compatible, 2 year warranty
ATE	24.5202-0103.2 / 24.5203-0103.2	3200–3800	Reinforced fittings, zinc plated
TRW	PFH40520 / PFH40521	2800–3300	Easy installation, new nuts included
Febi Bilstein	24520 / 24521	2000–2500	Budget option, requires thread inspection

If you decide to save money and buy non-original tubes, be sure to compare them with the dismantled old ones - the length and angles of the bends must match up to a millimeter. Otherwise, the tubes will be tense or, conversely, sag, which will lead to rapid wear.

Necessary tools and preparation

To replace rear brake pipes with Almera Classic you will need a standard set of tools, but there are also specific devices that you cannot do without. Here's the full list:

Open-end and spanner wrenches (10, 12, 14 mm)

Sockets with extension (for hard-to-reach nuts)

Special wrench for brake pipes (or adjustable wrench with thin jaws)

Pliers and round nose pliers

Hammer and wooden spacer (for carefully loosening stuck nuts)

Tripod to support tubes during dismantling

Brake fluid DOT-4 (not less than 0.5 l)

Bleeding hose and fluid container

WD-40 or similar for treating rusty joints

Protective gloves and glasses (brake fluid is toxic!)

-->

Before starting work, complete the following preparatory steps:

1. Place the car on a level surface and secure the front wheels with chocks. Raise the rear part on jacks or a lift, after loosening the wheel nuts.
2. Remove the rear wheels and brake drums (on models with drum brakes) or calipers (on disc versions). This will provide access to the tube mounts.
3. Clean all connections remove dirt with a wire brush and treat WD-40. Pay special attention to the nuts on the master cylinder and calipers - they often stick.
4. Prepare a container for draining brake fluid. When you disconnect the tubes, it will begin to flow out, so put the hose on the fitting in advance and direct it into the bottle.

⚠️ Attention! On Nissan Almera Classic with ABS when replacing tubes Be sure to disconnect the ABS sensor connector on the rear axle to avoid damage to the control unit. The connector is located next to where the tube is attached to the body.

If you are working alone, prepare in advance tube supports - they should not sag or bend. Use wire or special posts to secure them in their natural position.

Step-by-step instructions for replacing tubes

The process of replacing rear brake pipes with Almera Classic includes several stages. We will analyze each of them, taking into account the nuances characteristic of this model. Start with right side (in the direction of travel), since it is usually easier to access.

1. Dismantling old pipes

First disconnect the handset from master cylinder (it is located under the hood on the driver's side). To do this:

1. Release the tube fixing bracket by unscrewing the bolt with a wrench 10 mm.
2. Place the rubber cap (from the new pipe kit) on the cylinder fitting to minimize fluid leakage.
3. Carefully unscrew the tube nut with a special wrench, holding the fitting with an open-end wrench on 11 mm. If the nut does not budge, lightly tap the wrench with a hammer through a wooden spacer.

Next, move to the rear of the car:

4. Disconnect the handset from brake caliper or wheel cylinder (depending on brake type). Here you may need pliers to hold the fitting.
5. Release the tube from all fastenings along the body. On Almera Classic they are fixed with plastic clips or metal brackets - use a screwdriver to remove them.
6. Remove the old tube by carefully pulling it along the body. Do not use excessive force to avoid damaging adjacent elements.

2. Installation of new tubes

Before installation, compare the new tube with the old one - they should completely match in shape. Installation is performed in reverse order:

1. Pass the tube along the body, fixing it in the fasteners. Make sure it does not touch any sharp edges or moving parts.
2. Connect the tube to the caliper (or slave cylinder) by tightening the nut to torque. 15–18 Nm. Do not overtighten to avoid stripping the thread!
3. Attach the tube to the master cylinder after cleaning the fitting. Use the new O-rings included in the kit.
4. Reinstall all retaining clips and brackets. Check that the tube is not strained.

Repeat the procedure for left side. After replacing both tubes, proceed to bleeding the system.

3. Bleeding the brake system

Bleeding is necessary to remove air that entered the system when replacing tubes. For Almera Classic The pumping order is as follows:

1. Rear right wheel → rear left → front right → front left.
2. Place a hose onto the caliper (or cylinder) bleeder fitting and lower the other end into a container with brake fluid.
3. Have an assistant press the brake pedal 3-4 times and hold it down.
4. Unscrew the fitting ½ turn - liquid with air bubbles will begin to flow out. Close the fitting when the flow weakens.
5. Repeat the procedure until there is no air left in the liquid (bubbles stop coming out).

After bleeding all wheels, add brake fluid to the level MAX in the reservoir and check the system for leaks by pressing the brake pedal. It should be elastic, without “dips”.

Common mistakes and how to avoid them

Even experienced car owners make mistakes when replacing brake pipes, which later lead to repeated malfunctions. Here are the most common mistakes and how to prevent them:

• 🔧 Bend of tubes during installation. This narrows the lumen and impairs fluid circulation. Always ensure that the bend radius is at least 5 cm.
• 🔧 Insufficient tightening of nuts. Leads to fluid leakage. Use a torque wrench 15–18 Nm.
• 🔧 Using old brake fluid. When replacing tubes, the liquid in the system is already contaminated with wear products. A complete fluid change is required!
• 🔧 Ignoring fasteners. Unfixed tubes vibrate when moving and quickly fray. All clips must be in place.

Another common problem is thread damage on the fittings. To avoid this:

• Always use special wrench for brake pipes (or adjustable with thin sponges).
• Treat the connection before unscrewing WD-40 and let it soak in for 10-15 minutes.
• Do not use excessive force - if the nut does not fit, heat it with a hair dryer (but not with an open flame!).

If the thread is still broken, you will have to replace the fitting or the entire brake cylinder. On Almera Classic it will cost 3–5 thousand rubles per part plus labor.

What should I do if the pedal remains soft after replacing the tubes?

If after bleeding the brake pedal remains “wobbly”, check:

1. Tightness of all connections - even a microcrack allows air to pass through.

2. The liquid level in the tank - when pumping, it could fall below the minimum.

3. Condition of the master cylinder - wear on the cuffs also causes a soft pedal.

4. Presence of air in the ABS block (on models with ABS a special scanner is required for bleeding).

When to contact the service?

Although replacing the rear brake pipes with Nissan Almera Classic can be done with your own hands; in some cases it is better to trust the professionals. Contact the service if:

• 🔧 You discovered corrosion on the brake master cylinder or calipers - this may require complex repairs.
• 🔧 When pumping no liquid comes out through one of the fittings - the line may be clogged.
• 🔧 Your car is equipped ESP or VDC system — diagnostic equipment will be required for bleeding.
• 🔧 You are not confident in your abilities - mistakes when working with the brake system can cost your life.

The cost of replacing tubes in the service varies from 3 to 6 thousand rubles (excluding spare parts). If you decide to go to a car service center, choose proven stations with good reviews - saving on the quality of work is unacceptable here.

For self-replacement, the main thing is take your time and follow the instructions. Average working time for beginners - 4–6 hours, for experienced car owners - 2–3 hours. Don't forget that after replacing the tubes, you need to check the brakes while driving: accelerate to 40–50 km/h and perform several gentle braking runs to ensure smooth operation of the system.

FAQ: Frequently asked questions about replacing tubes

Is it possible to replace only one tube if the second one is in good condition?

Technically yes, but highly not recommended. The tubes wear out at about the same rate, and if one has become unusable, the second will soon follow suit. In addition, new and old tubes may have different resistance to fluid flow, which will lead to uneven braking. Always change set.

What brake fluid should I fill after replacing the pipes?

For Nissan Almera Classic the manufacturer recommends a class fluid DOT-4. You can use the original Nissan Brake Fluid (article KE902-99932) or analogues from ATE, Castrol, Liqui Moly. Do not mix liquids of different classes (DOT-3, DOT-4, DOT-5.1) - this will lead to destruction of the seals.

How often should you check the condition of your brake pipes?

Minimum inspection frequency: every 20 thousand km or once a year. Pay special attention to:

• Places where the tubes are attached to the body (often chafed).
• Areas near the fuel tank (possible corrosion from condensation).
• Connections with calipers and cylinders (leaks from under the nuts).

If the car is operated in aggressive conditions (salty roads in winter, off-road), inspect the pipes every 10 thousand km.

What to do if the fitting breaks when unscrewing the tube?

This is one of the most unpleasant situations. Solutions:

1. If the fitting is broken on the caliper or working cylinder, replace the entire assembly. For Almera Classic rear cylinder costs approx. 1.5–2 thousand rubles.
2. If the fitting is on the master brake cylinder, try drilling out the remaining parts and cutting a new thread with a tap. In extreme cases, the cylinder will need to be replaced (5–7 thousand rubles).
3. In both cases after repair be sure to bleed the system, since metal debris could get there.

Is it possible to drive with a damaged brake pipe if there are no leaks?

Absolutely not! Even a microcrack under pressure can instantly disperse, leading to complete loss of brakes. The brake system operates under pressure up to 100 atmospheres — Risking your life to save money on repairs is unacceptable. At the slightest suspicion of tube damage start replacing immediately.