Clutch line replacement DIY

vantaam5 · 17th March 2010, 23:39

Change today a leaking clutch line.

New line:

Open bonnet,remove pollen filter housing(don't forget to disconnect bonnet switch) in order to get to the brake fluid reservoir.

Remove bolt(Phillips head) of carpet side panel and slide it backwards to remove it.

Remove plastic panel under dash board(Phillips head and T10 screws)

Remove screw of bonnet lever(Philips head) and the plastic bolt behind it(flat head).

Pull up the inner plastic rocker cover and remove it.

Pull the whole dead pedal unit backwards out.Disconnect trunk switch.Remove the assembly completely.Is a bit PITA to do...

Remove the plastic cap in the carpet behind the clutch pedal and pull the carpet away.

Get the car front on jack stands,remove plastic tray under gearbox.

Remove the nuts from heat shield(10mm socket) and pull it down abit in order to get a bit space.

Remove slave cylinder from gearbox(13mm socket), remove circlip of the clutch line connector with screw driver and let the fluid drip in a bucket.

Remove circlip of the line on the master cylinder and put some paper towels there to catch brake fluid.

Push old line out through the whole in the fire wall behind accelerator pedal.

Insert new line ffrom underneath the car with the protection caps still on.
Have to also pull it a bit from the inside in until it is in position.Connect line on the master cylinder.

Connect line on the slave cylinder and dont forget the bracket!

push rubber gromet in the fire wall(another slight PITA).

Install slave cylinder and bleed the clutch system.
Check for leaks and assemble the rest.

Get a cold beer......

russap5 · 17th March 2010, 23:59

Thanks for the DIY. What are the symptoms of a leaking clutch line?

vantaam5 · 18th March 2010, 00:38

Drew,sometimes the pedal is a bit too soft.But you see only from underneath if it is sweating.Worst case is the line blows and the pedal stays on the floor.Have to change anotherone next week,also a few members had theirs changed yet.
Costs about 30$ and an hour labour.
Better than getting stranded somewhere....

OC e39r · 18th March 2010, 03:26

Here is another thing to change soon,O man.. my list for the 100k maintenance is growing long
Vantaa.. can you post the part no. and save us some search ?
Regards

herrubermensch · 18th March 2010, 05:01

Raikku, thanks for the DIY! This is great! Did you use a stock clutch line or a custom one? Looks stock, but I thought you were going custom.

--Peter

Quicksilv3r · 18th March 2010, 05:50

Wow great write-up! I'll put this on the list as well.

Zubehor · 18th March 2010, 09:31

great write-up thanks for sharing

vantaam5 · 18th March 2010, 10:11

Thanks,everyone for the comments!
Part number is:21526751171

Peter,had a problem with the connection on the master cylinder side with the braided hose I built.Ordered a different connector which might take another two weeks until it is here

I did not want to take chances with my old line and the new OEM part is so cheap.You know I am a bit paranoide on failing parts,so the whole last week each time I used the clutch,I waited for the pedal to stay on the floor

Have now more relaxed driving with the new line in until the rest for my braided line comes.