A brake system is composed of three primary elements: the master cylinder that sends fluid through the lines, the lines themselves, and the slave cylinders (brake calipers) that squeeze on the pad and stop the car. Though engineered to outlive the car by several years, lines can sometimes become rusted, damaged or dry-rotted, causing anything from a slow leak and soft pedal to a catastrophic accident.
Physical Damage
The most common type of physical damage is chafing (scraping) of the flexible rubber portion of the line that connects the wheel cylinder to the metal chassis lines. Though these lines are generally suspended by clips from the factory, these often plastic clips work loose or break, causing the line to rub against or become pinched by suspension components.
Dry-Rotting
Rubber brake lines are made of a vulcanized rubber very similar to a tires, and so are subject to dry-rotting. Over time, vital chemicals are leached from the rubber, causing it to lose its elasticity and form small cracks that may eventually leak. This condition is normal for cars of a certain age, but may be accelerated if the vehicle is regularly driven over salted winter roads.
Rust
Though brake lines are generally made of aluminized or galvanized metal, almost all will eventually rust over time. This will usually happen where the line passes through a low point in the frame, or where it is secured to the frame with a metal clip. Like dry rot, this is normal for older cars, but will happen significantly faster if the car is regularly driven over salted roads.
Artificial Corrosion
By definition, an acid is a chemical that dissolves metal. Many batteries, especially those found in older cars, leak a certain amount of acid. Though most of this acid is diluted and causes little harm to the vehicle, it is quite possible for some of the dried chemical to land on your brake lines, eating through their protective coatings and drastically hastening the corrosion process.
Line Upgrade
Steel-braided brake lines are the line of choice for replacing worn-out rubber, and are proven much safer. Not only will these flex lines far outlast their stock counterparts, they are also designed not to bulge as much under system pressure. This means you can expect a great deal more feel and response from a braking system with braided lines than one with stock rubber.
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