Underbody Line Repair

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Identifying Tube Cut Length Locations

1. If repairing an underbody refrigerant line, recover the refrigerant from the refrigerant system. Refer to R-1234YF REFRIGERANT SYSTEM RECOVERY  .
2. If repairing an underbody coolant line, drain the engine cooling system. Refer to the appropriate Engine Cooling System information .
3. Disconnect and isolate the negative battery cable.
4. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
5. Remove the underbody mounting brackets as necessary to gain access to the underbody line(s) needing repair. Refer to LINES, A/C UNDERBODY, REMOVAL AND INSTALLATION .
6. Mark the cut location(s) on the underbody line(s) needing repair. Check the Tube Length chart for the minimum amount of straight tube required (dimension A) for proper connector fitting installation.
7. Using a small pipe cutter or another suitable tool, carefully cut the underbody line(s) needing repair at the location(s) previously marked.
   TUBE LENGTH
   
   

   Tube Size	Minimum Tube Length Required
   	Dimension A Standard Installation	Dimension A Jaw Reversed Installation
   3/8 in.	28.5 mm (1 1/8 in.)	19 - 28.5 mm (3/4 - 1 1/8 in.)
   1/2 in.	28.5 mm (1 1/8 in.)	19 - 28.5 mm (3/4 - 1 1/8 in.)
   5/8 in.	31.7 mm (1 1/4 in.)	22.2 - 31.7 mm (7/8 - 1 1/4 in.)

   Courtesy of CHRYSLER GROUP, LLC

8. Size a replacement line, same size diameter and length as the portion of the line(s) removed.
   NOTE:

   A minimum of 28.5 mm (3/4 in.) of the line end must be cleaned in order for the connector fitting to properly seal the repair area.

9. Clean the ends of the line(s) a minimum of 28.5 mm (3/4 in.) (dimension A) using the Scotch-Bright® pad provided with A/C Line Repair Tool Kit (special tool #8456A, A/C Line Repair Tools). Clean the line end(s) with a rotational motion around the line to avoid longitudinal scratches in the line.

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   Locating Connector Fitting

10. Select the proper connector fitting (1) for the size of the underbody line being repaired. See the Connector Fitting chart.
11. Apply one drop of Lokprep® sealing compound provided with A/C Line Repair Tool Kit (special tool #8456A, A/C Line Repair Tools) onto each line end (2).
12. Insert the line ends into the selected connector fitting and rotate the connector fitting a complete turn to evenly distribute the sealing compound.
    CONNECTOR FITTING
    
    

    Description	Mopar Part Number
    3/8 in.	5069 002AA
    1/2 in.	5069 003AA
    5/8 in.	5069 004AA

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13. Select the proper size jaws (1) for the line being repaired from the A/C Line Repair Tool Kit (special tool #8456B-4, 5/16" (8mm) Foot Assembly). See the Jaw Size chart.
14. Assemble the jaws into Tool Body (special tool #8456-3, Installer Body) (2) (in Kit 8456A).
    1. For standard installation, install the jaws with the rubber gripping pads (3) facing outward. See the Tube Length chart.
    2. For reversed installation, remove the rubber gripping pads and install the jaws with the rubber gripping pad area facing inward. See the Tube Length chart.
    JAW SIZE
    
    

    Description	Miller Part Number
    3/8 in.	8456-1
    1/2 in.	8456-4
    5/8 in.	8456-2

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    NOTE:

    The connector fitting ends must be positioned into the counterbore of the jaws in order for the connector fitting to properly seal the repair area.

15. Install the connector fitting (1) and the line ends (4) into the counterbore of the jaws (5).
16. Hold Tool Body (special tool #8456-3, Installer Body) (2) with a 3/8 inch breaker bar and turn the forcing screw (3) clockwise.

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    Bottoming Out Connecting Fitting Collars

    NOTE:

    The lines must be kept fully inserted into the connector fitting to obtain a leak free joint.

17. Turn the forcing screw (1) clockwise until both connector fitting collars (2) have bottomed out on the center shoulder of the connector (3).
18. Loosen the forcing screw and remove Tool Body (special tool #8456-3, Installer Body) (4) and the jaws (5) from the repaired line(s).
19. Install the underbody mounting brackets as necessary. Refer to LINES, A/C UNDERBODY, REMOVAL AND INSTALLATION .
20. Remove the support and lower the vehicle.
21. Connect the negative battery cable.
22. If repairing an underbody coolant line, fill the engine cooling system. Refer to the appropriate Engine Cooling System information .
23. If repairing an underbody refrigerant line, evacuate and charge the refrigerant system. Refer to R-1234YF REFRIGERANT SYSTEM EVACUATE  and R-1234YF REFRIGERANT SYSTEM CHARGE  .