Arrived in our family retreat for the weekend, with a jet ski in tow behind the 240D, at about 10 pm last night. Once off the highway, it became apparent the clutch was no longer functional. This morining it seemed the hydraulic line from the master cylinder to the slave cylinder was leaking at the connection to the slave cylinder. Attempting to tighten the joint proved fruitless. I could not get a turn at all, which left me to conclude the joint was tight and still leaking. Given that it was leak tight the day before this trip started, it seems likely the leak is a result of a crack in the tubing at the nut. I am in a location where a new piece of tubing is out of the question, as is a new tube nut. So, I think I can get a tube flaring tool and cut the exiting tube back an inch or so, and reinstall it. My question is, has anyone tried this, and is the tube in fact flared at the end? Thanks, Jim

__________________
Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)

Well, I have looked through chassis One and Two for 123's....and the 616 manual... and the only reference to manual clutches is in the section on cruise control... showing the switch on the clutch pedal which disengages it ...

All steel tubing that I know of used on brakes is of the double flare style... not easy to duplicate on short pieces and them fit well...

How about cleaning it up and putting a couple of layers of heat shrink tubing around it to perhaps just get you home.... ?
Is it in the supply region or the pressure region ?

It's been several years since I've had that joint apart, but I am reasonably sure it is a flared tubing joint. My guess is the tubing has cracked near the nut, due to high stress. When you pressure it up by pushing in the clutch, it opens up and squirts out fluid, but won't actuate the slave. Your plan of cutting it off an inch back and reflaring sounds like a good plan....'hope it works for you.

__________________
1976 240D
1987 560SL
2007 E320 Bluetec
1998 C280 (now son’s car)
1982 240D Manual - Sold

jim

I just say your post. I have one of those tubes lying on my bench and it is flared.

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

Double flared or just regular single?

If its double, it seems like the single COULD get him home if he got it tight enough. At the very least...its sure easy to get to!

"Double flared or just regular single?"

It looks just like a reguler flare to me. I 've done copper tube but I would think that steel tube would be rather tough.

Jim....some vacation, at least its not heard to get to compaired to a 300. I could send you the one I have but you proly got her fixed by now, let me know, I could get it off to you Tues morning.

__________________


1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

http://www.google.com/search?hl=en&q=double+flare+brake+steel&btnG=Google+Search

Thanks for the replies. I will be picking up the tool to cut the line later today, and then I will find a tool tomorrow to fix the unit. Jim

__________________
Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)

Hi All.

Just a quick question while on the 240D clutch subject. My clutch pedal is too low. Is there an adjustment that can be done to bring it up?

Thanks in advance.

__________________
Dropout

1978 240D work in progress

If there is...it would have to be in the linkage feeding the master clutch clyinder...not the slave.
Are you sure there are no air bubbles?

i would think it is a double flare. perhaps a single flare will get you home because it is a clutch and not a brake line. double flare it if you can get the tools.

if not it is possible to drive wo a clutch slave. not recommended unless it is an emergency but if you are careful you can start up in gear with the motor off and start it then ease off the throttle and slip it out of gear then allow the rpm to drop and slip it into the next gear. and dont force it if it wont slip in just adjust throttle til the engine speed matches the desired speed in the gear you are in and it will slip right in. careful though you can break stuff if you ham and jam it.

__________________
[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

Well, I could not assemble the tools needed to remove the line, cut it and flare the end, then reassemble. Not that it was complicated, but it was the 4th of July weekend and there was nothing around that was open. So, I drove it 300 miles home. I only crunched gears once, trying to downshift from 4th to 3rd. The "trick" was to find what speed the car runs at while idling in each gear, then only run up to that speed in the lower gear, then shift. This was consistently "crunch free" and worked beautifully. Of course most of the driving was in 4th gear, and the method of getting to 4th gear resulted in lugging the engine a bit, but all worked out fine. I am busy at work and have not had time to tackle the job. I may end up replacing the line and the slave cylinder since I was unable to budge the nut (which looks a little worn, and seems to be a 12 mm nut). But it looks like cutting the line an removing the cylinder is the way I will go. Jim

__________________
Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)

on the clutchless shifting.

__________________
[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.