Assembling a hose end looks tricky at first, but it’s actually very simple. It’s important to make sure you follow the proper procedures to ensure correct assembly, reliability, and performance. Remember, hoses fittings aren’t just for looks or for delivering fluids, they are safety items designed to ensure that the fluids they are carrying get to where they need to go without leaking. Failure properly assemble these parts can lead to poor performance or leaking flammable fluids, and we all know that’s not good!
Step 1: Cut the hose to desired length.
Measure twice and make sure the hose is the length necessary to go from Point A to Point B. If necessary you can try cutting it a bit longer than you actually need to, then shortening it up a bit until the length is just right for your application. It’s important to ensure you get a clean perpendicular cut on the hose, as deviations can cause the hose to not seal properly inside the hose end, leading to leaks.
Note: Cutting the hose requires special tools. We don’t recommend using metal cut-off wheels or abrasive cutting tools as these can cause a large amount of rubber dust to build up in the hose which must be cleaned prior to continuing the assembly process. Failure to clean can result in the dust entering your parts, causing damage. We recommend using either a hydraulic hose cutting blade or a 350 MCM electrical cable cutter.
Step 2: Insert hose into the socket/collar
Place the socket in a vise (preferably with our Billet Vice Jaw Insert) and insert the hose until the end of it is close to the bottom of the threads. There should be an approximately 1/8″ (2-3mm) between the threads and the end of the hose. Getting this right is important because if it’s not all the way in, the hose may not seal against the hose end body. When inserting the hose, be sure to keep the braiding intact, particularly if you’re using nylon braided hose. If it gets too frayed, it will increase the outer diameter of the hose and make it difficult to insert into the socket.
Step 3: Lubricate the hose end body
Apply a small amount of oil to a rag and use the rag to apply the oil to the hose end body. Only a thin layer is necessary. Do not use anti-seize or grease. Be sure to cover the threads, nipple, and if desired, lubricate the threads on the socket and inside the hose. Only a small amount of oil is necessary to help the parts slide. Don’t go nuts.
Step 4: Assemble!
You may assemble the socket and body with either part in the vise. You may find one method more comfortable than the other. Either way, the procedure is the same: Hold the hose with one hand to prevent it from moving, then push the nipple into the hose through the socket to ensure proper engagement, then gently start the threads. If you feel ANY kind of binding then stop immediately. These parts are made of aluminum and are very soft, if there is binding then this means that there is a flaw in the machining or you are cross-threading the parts. They are machined very precisely and if it doesn’t go together smoothly then something is wrong.
You should be able to get the hose end body to within about 1/16″ (1-2mm) of the socket. This is best to ensure a proper seal and to make sure it looks good.
Step 5: Clean and Test
Clean the hose and hose end with a solvent to remove any excess oil or residue, then immediately pressure test the completed assembly. If you encounter any leaks, determine the reason why and take steps from there to resolve the leaks. If you do not have access to a pressure tester, then when the hose assembly is installed in the vehicle then ALWAYS make sure you observe for any leaks or issues before putting the vehicle into service.