Aluminum A/C Hose Repair


Aluminum air conditioning tubing and hose in cars and trucks can sometimes go bad or fail. When this happens, you can repair the hose with a repair kit, such as the Aluminum E-Z Clip. You can reuse the terminal connection for the original hose, and replace the part of the hose that has failed.

Things You'll Need

  • Aluminum E-Z Clip System
  • Nylon brush
  • Hacksaw
  • Metal file
  • Degreaser
  • Cloth
  • Bench vice
  • Brass ring
  • Counterbore
  • Aluminum brazing flux
  • Torch
  • O-rings
  • Open the hood of the vehicle and set the support bar. Locate and remove the part of the air conditioning hose that has failed. Scrub the tubing and hose with a nylon brush to remove any dirt and debris.

  • Find and make a scribe line on the tube. The scribe line needs to be at least 3/16 of an inch from where the hose meets the tube assembly. Make another scribe line on the opposite end of the tube assembly.

  • Cut one end of the tubing on the scribe line you made in Step 2 with the hacksaw. Repeat this step on the opposite end of the tube assembly.

  • File the ends of the cut pieces of tubing with a metal file, to remove any burrs. Remove any dirt and residue from the outside of the tube with the degreaser and cloth. Blow out the inside of the tube with an air compressor.

  • Insert the tube assembly into a bench vice. Place the brass ring into the counterbore, and add aluminum brazing flux to the inside and outside of the counterbore. Place the counterbore into the end of the cut tube.

  • Braze the nipple to the end of the aluminum tube with a torch. If you are not familiar with brazing techniques, contract an auto service industry expert or technician to braze the nipple.

  • Insert one of the O-rings over the end or cone-shaped section of the nipple. Insert the second O-ring over the first until it fits into the groove. Connect the repaired tube assembly to the hose to complete the project.

Tips & Warnings

  • Brazing is a technique that joins two pieces of metal together by using heat from a torch to melt the metal.
  • Steam can come out of the fitting when brazing and can cause burns.

Related Searches


  • Photo Credit old engine image by John Sfondilias from
Promoted By Zergnet


You May Also Like

  • How to Repair a Car With Duct Tape

    We have all heard the jokes about the 1000 uses for duct tape, but beneath those stereotypes and jokes lies the lists...

  • How to Fix Leaks on AC Units

    AC units allow us to escape from the brutal heat of the summer months. We can retreat into our cooled "oasis" and...

  • How to Repair an Air Hose

    An air hose can crack or puncture for a variety of reasons, and they oftentimes break in very inconvenient spots. The risk...

  • How to Repair an Automotive Air Conditioning Line

    New air conditioning hose assemblies are expensive. Oftentimes, a simple repair can save hundreds of dollars. Repairing air conditioning lines falls into...

  • How to Crimp AC Hose Fittings

    Air conditioner hose fittings are metal hose collars that attach a high-pressure rubber hose to an AC coolant pipe. These connections need...

  • How to Repair Car Hoses

    If the radiator hose in your vehicle is leaking, it can cause serious damage. With a simple repair kit you can fix...

  • How to Repair a Steel Braided Hose

    Steel braided hoses are identical in almost every way to regular garden hoses used by homeowners across the nation. The only difference...

  • How to Repair an Aluminum Pipe

    Aluminum pipes are commonly used with water systems because aluminum is highly resistant to rusting and corrosion caused by water exposure. Another...

  • How to Splice a Rubber AC Hose

    Although the AC, or air conditioning, lines in most cars today are aluminum, there are still plenty of older cars out there...

  • How to Stop an Auto AC Leak

    Automotive air conditioner leaks can pose a major repair problem, and if your vehicle has a major issue, you will likely need...

  • How to Repair an Aluminum AC Line

    Air conditioners have many parts that require routine maintenance. Among them are the condenser coils, which should be cleaned on a regular...

  • How to Repair an Aluminum AC Pipe

    Air conditioning lines, pipes and coils are typically made of aluminum. This metal is durable, light weight and somewhat impervious to weather...

Related Searches

Check It Out

How To Travel For Free With Reward Points

Is DIY in your DNA? Become part of our maker community.
Submit Your Work!