Aluminum A/C Hose Repair

Written by cameron easey
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Aluminum A/C Hose Repair
Aluminium hoses in the engine compartment may need repairs (old engine image by John Sfondilias from

Aluminium 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.

Skill level:

Things you need

  • Aluminium E-Z Clip System
  • Nylon brush
  • Hacksaw
  • Metal file
  • Degreaser
  • Cloth
  • Bench vice
  • Brass ring
  • Counterbore
  • Aluminium brazing flux
  • Torch
  • O-rings

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  1. 1

    Open the bonnet 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.

  2. 2

    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.

  3. 3

    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.

  4. 4

    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.

  5. 5

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

  6. 6

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

  7. 7

    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 and 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.

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