Got a "Check Brake Fluid Level" warning and discovered leaking, rusted brake lines. This is more of a data point than a problem given my habits but I think it points out a weak spot.
2007 Cayman
2.7 5 spd with 188k and seven winters in Northern New York. Amazingly my car shows very few signs of rust. I have never had the under-panels off until tracking down the dripping brake fluid. I would like to hijack my own post to say be very careful with the plastic nuts and rather light duty studs that hold the under-pans up. I broke one even after penetrating oil and being very careful. I think I would suggest squeezing the plastic nuts all around with pliers or something or maybe a light whack straight-on to try and break that bond from the corrosion. My brake lines on the driver side had a section of rust only about 12" long that took in the junction block that I assume is the joint between front and rear when building the car (if it has a bigger purpose like a cross-over, please enlighten me because I'm about to eliminate it). The lines had deteriorated to the point they didn't hold fluid. The block and fittings are gone too. Flushed my brake fluid at 60k and at 160k. To any of you on a path to high miles or if you dabble in salt/calicum chloride, I would suggest pulling your covers and treating your brake lines to some sort of schnord that will protect them better than the factory coating (which is pretty good). My plan (worked on my '95 Jeep) is to splice-in two new sections and just go back to where the lines are in good condition in both directions. The patch(s) will be about 16' long, maybe more when I look closer. They're better in exposed areas than in this spot under the panel. Planning to use 3/16" line although I assume the originals are 5mm (they measured .190" with flakey coating). Hoping I can work with the .010" difference. I'm officially down from this and need a speedy comeback so if anyone sees a flaw in my logic, please save me.
I didn't expect anyone to bite on this one so I thought I would give you some pictures to chew on.... First thing, the block is simply a through-block so no problem eliminating it. Secondly, 3/16 line and fittings worked-in fine and the problem has been eliminated for now. When this problem resurfaces, I will probably just replace lines from stem to stern. Hope this helps, C.
