NHTSA Complaint #10380351 — 2002 SUZUKI XL-7

CONDENSATION FROM VEHICLES AIR CONDITIONING DRIPS ONTO THE INSULATION AROUND BRAKE LINE THAT IS SUPPOSED TO PROTECT BRAKE LINE FROM EXHAUST MANIFOLD HEAT. LIVING IN TEXAS THE VEHICLE RARELY IS TURNED ON WITHOUT THE AIR CONDITIONING. THE CONTINUED SATURATION, DRYING AND VIBRATION OF NORMAL DAY TO DAY USE CAUSED A LEAK IN ONE OF THE TWO BRAKE LINES LEADING TO THE REAR OF THE VEHICLE. THIS WAS DISCOVERED AFTER OWNER REPORTED SPONGY FEELING AND LOSS OF BRAKE HOLDING STRENGTH WHILE IN STOPPED POSITION. UPON FURTHER INSPECTION IT WAS NOTICED BOTH BRAKE LINES BEHIND PROTECTIVE INSULATION HAS SEVER OXIDATION CLOSEST TO THE ENDS THAT ARE ATTACHED TO AN ADAPTER. FIX THAT I EMPLOYED WAS TO BYPASS THE EXTENSION THAT RAN FROM THE TOP OF THE ENGINE DOWN THE PASSENGER SIDE, ENTERED THE INSULATED EXTENSION AND THEN ENTERED THE ADAPTER THEN INTO THE REAR BRAKE LINES. I WAS ABLE TO BYPASS ALL THE UNNEEDED JOINTS WITH 2 48 BRAKE LINES AND 2 COUPLINGS BOUGHT FROM LOCAL AUTO PARTS AND REROUTED LINE FROM DRIVER SIDE DOWN ACROSS REAR SIDE OF UNDERCARRIAGE THEN DIRECTLY INTO REAR BRAKE LINE. THE A/C NO LONGER DRIPS ONTO THE BRAKE LINE.