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Vacuum Hose Repair

WARNING: This page is about a different car, the 2003 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Special Tool (Vacuum Hose Repair)
G01388558Courtesy of FORD MOTOR CO.
  1. Measure the length of the damaged area of the mini-tube vacuum hose.
  2. Cut a piece of standard 3mm (0.125 inch) inner diameter vacuum hose approximately 25 mm (1 inch) longer than the damaged area of the mini-tube vacuum hose.
  3. Cut off the mini-tube vacuum hose on each side of the damaged area.
    4. WARNING: Read the warning information on the product label. Failure to follow these instructions may result in personal injury.
  4. Dip the mini-tube hose ends in commercially available paint thinner containing methyl ethyl ketone (MEK). This solvent will seal the mini-tube in the vacuum hose.
  5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (0.375 inch) into the ends of the standard 3 mm (0.125 inch) service vacuum hose section.
    Fig 2: Inserting Ends Of Mini-Tube Vacuum Hose Into Ends Of Standard Service Vacuum Hose Section
    G01388559Courtesy of FORD MOTOR CO.
  6. Shake the service joint after assembly to make sure the O-ring seal solvent is dispersed and the vacuum line is not plugged.
  7. Test the system for a vacuum leak in the repair area.
    • Use the Vacuum Tester or equivalent.
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