While replacing the brake master cylinder, I noticed a swollen, cloth covered hose coming out of the reservoir and through the firewall.
I believe this line is feeding the clutch master cylinder.

Came up with this as a part number: 003-997-12-52 (can anyone confirm?)

From what I understand, this line is not pressurized, but gravity fed.
Is it possible to change this line without bleeding the clutch?

Who's done this?

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1981 240D 4sp manual. Ivory White.

IIRC it can be done without bleeding the clutch and it is normal braided cloth hose. Fill the hose very slowly to allow air to escape and attach it to the reservoir and keep filling the reservoir. The hose is in the reservoir side not the pressure side so it will be fine.

Good luck!!!

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"Rudeness is a weak man's imitation of strength" - Eric Hoffer

Hi Shern,

The new replacement from the dealer is plastic instead of the braided hose. Just put one on my 300D.

You can order the original braided hose like you’ve got now from VW shops or Bel Metric if you don’t want to use the new plastic one.

Good luck bleeding the clutch when you replace the line. Maximan1 and I had the most success connecting the front pass brake bleeder to the slave bleeder and back filling the clutch system.

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1983 300D Midnight Blue
4 speed, W115 intake mani, non-EGR exhaust mani, KKK K26, 3 pc Euro bumpers, Lo-spec Euro headlights, AL129X, hubcaps, custom A/C

1987 300TD Smoke Silver
Euro headlights, thermostat relocation, coolant bypass mod, rebuilt Becker + Jehnert + Helix audio, OEM Oris roof boxes and surfboard racks, Euro towbar

1983 300TD Reed (Moss) Green / Dark Olive MB Tex Euro spec

1983 300TD Silver Blue / Blue cloth Euro spec, OM648 and 722.6, 15" hubcaps, W126 S2 brakes

Careful, the plastic 45 degree fitting coming out of the top of the master the line connects to is unobtanium, and easy to break. Grest part to whip up on a 3D printer.

As mentioned, this section of the clutch system related to the reservoir does not need to be bled or pre filled, simple to replace

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This post brought to you by Carl's Jr.

Oh boy. I recall reading that somewhere in the archives.
Any tips or words of encouragement for removing it?

Heffe- seems like the new plastic version is an upgrade?

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1981 240D 4sp manual. Ivory White.

Its a grommet, it pops out. The hose, old and new types work the same way, just dont put too much sideways force on that little bit of 35 yesr old plastic. Id pop it out of the master first, then carefully work it out of the old line out of the car.

In all this is a reslly quick and easy job so dont feel any worry

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This post brought to you by Carl's Jr.

Ah, roger that.

To be perfectly clear, the grommet is what the 45 degree elbow slots into, which is topside the clutch master cylinder? So I gently pull the elbow from the grommet, and then remove the elbow from the hose.

Appreciate the hand holding. Unobtainium pertaining to drive-ability is not something I care to experience at present.

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1981 240D 4sp manual. Ivory White.

Perhaps they are remaking them - I was able to order one from the Classic Center a few weeks ago.

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1983 300D Midnight Blue
4 speed, W115 intake mani, non-EGR exhaust mani, KKK K26, 3 pc Euro bumpers, Lo-spec Euro headlights, AL129X, hubcaps, custom A/C

1987 300TD Smoke Silver
Euro headlights, thermostat relocation, coolant bypass mod, rebuilt Becker + Jehnert + Helix audio, OEM Oris roof boxes and surfboard racks, Euro towbar

1983 300TD Reed (Moss) Green / Dark Olive MB Tex Euro spec

1983 300TD Silver Blue / Blue cloth Euro spec, OM648 and 722.6, 15" hubcaps, W126 S2 brakes

It's just a plastic 45 degree fitting. You push one end into the fitting on the clutch master, and one end into the new hose.

The updated hose is the same on both ends. Plastic outside with a rubber grommet/seal inside.

You can use the original style hose if you'd like. I wouldn't call the new style an upgrade myself; merely something else to get brittle and break. I was surprised at the updated part when it arrived, as it didn't look right. But it fits...

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1983 300D Midnight Blue
4 speed, W115 intake mani, non-EGR exhaust mani, KKK K26, 3 pc Euro bumpers, Lo-spec Euro headlights, AL129X, hubcaps, custom A/C

1987 300TD Smoke Silver
Euro headlights, thermostat relocation, coolant bypass mod, rebuilt Becker + Jehnert + Helix audio, OEM Oris roof boxes and surfboard racks, Euro towbar

1983 300TD Reed (Moss) Green / Dark Olive MB Tex Euro spec

1983 300TD Silver Blue / Blue cloth Euro spec, OM648 and 722.6, 15" hubcaps, W126 S2 brakes

Yes, you got that right. Brake master reservoir > braided cloth hose/new updated plastic hose > 45 degree plastic connector > rubber grommet at highest point of clutch master on pedal assembly.

It's a ***** and a half to contort yourself under there and get it done. Practice your yoga beforehand.

Try to remove the hose from the 45 degree connector without pulling the connector out of the clutch master cyl. There isn't much room to get that thing back into the clutch master cyl. I ended up having to disconnect the clutch master cyl from the pedal assembly to get it in properly.

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1983 300D Midnight Blue
4 speed, W115 intake mani, non-EGR exhaust mani, KKK K26, 3 pc Euro bumpers, Lo-spec Euro headlights, AL129X, hubcaps, custom A/C

1987 300TD Smoke Silver
Euro headlights, thermostat relocation, coolant bypass mod, rebuilt Becker + Jehnert + Helix audio, OEM Oris roof boxes and surfboard racks, Euro towbar

1983 300TD Reed (Moss) Green / Dark Olive MB Tex Euro spec

1983 300TD Silver Blue / Blue cloth Euro spec, OM648 and 722.6, 15" hubcaps, W126 S2 brakes

No kidding, my back still hurts from my attempt lol

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Milan Brown 1979 240D, rebuilt OM617.952 turbo diesel, rebuilt 722.315 transmission (my only daily driver)

Instagram: @maximed93

The braided line is still available from the dealer. Sold by the meter, so you can actually get about three clutch hoses from the one segment.

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Watch him go!!! link

#dontdealwithkahlil

Hot tip! Do you recall a part number? Or Dimensions?

Jeff - thank you, sir. I had to replace the clutch master cylinder pushrod once, so I know about the pretzel.

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1981 240D 4sp manual. Ivory White.

Lemme try to dig that up for you

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Watch him go!!! link

#dontdealwithkahlil

I appreciate it.

Been trying to find the Hose ID. I'm reading either 7mm or 8mm.

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1981 240D 4sp manual. Ivory White.