It is better to use a metric flaring tool to form the double flares, even though you are using 3⁄8 tube nuts. A 3⁄8 flaring tool will work, but it will put deep crimps into the 10mm tubing. Now the line ends can be joined with a standard 3⁄8 tubing union. 10mm and 3⁄8 line are close enough in size that in a pinch, standard 3⁄8 tube nuts can be drilled out to fit over the 10mm line, then double-flared in place. Unfortunately, 10mm metric tubing nuts and unions are not readily available. The best way to patch a cut cooler line is to double-flare the lines and join both ends with a tubing union. Replacement 10mm tubing is still very hard to come by, and most parts stores cannot even order it (see source box). Just as with standard 3⁄8 tubing, options include tubing nuts and union, compression fittings or rubber hose (see figures 4a, 4b and 5). If it is necessary to cut the line there are a few options to patch the 10mm tubing. This saves a lot of time re-installing the line, but, unfortunately, if it ever needs to be removed again you are back to the same problem. This removes a small amount of the expanded thread material from the line nut, making the line easier to re-install (see Figure 3). However, once the nut is tightened, the expanded threads make it very difficult to remove and re-install.Ī quick fix to make the line easier to re-install is to chase the threads with a 16mm x 1.5mm thread die or spindle thread chaser (see source box). Even with new parts the line nut will install easily. These female fittings have no threads near the bottom, so as the nut is tightened, the leading threads of the male nut expand or flare out (see Figure 2). The reason these fittings are so difficult to remove is that the line nut expands as it is tightened into the fitting. Nobody likes spending two hours on one line! Even after the line has been removed, the line nut will be just as hard to re-install. This is no picnic on cramped 4WD trucks with driveshafts and torsion-bar suspension in the way. What is especially frustrating about these applications is that the line nut often will break loose and turn easily for one or two turns and then lock up tight.
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