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Old 06-08-2009, 03:49 AM
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Join Date: May 2009
Location: Durban, South Africa
Posts: 43
Changed hose to Clutch Slave Cylinder w202 C200

Hi All,

I replaced part of the line running to my clutch slave cylinder on the weekend and thought I’d share my experience.

The section I replaced run from the slave cylinder, over the gearbox, and to a connection coming out from the body. This section is a solid hose from the slave cylinder and joins to a flexi hose at the top of the gear box. Mine was leaking at that join so I replaced the whole section.

I thought this was going to be a simple job, but it turned out to be more of a mission than expected….doesn’t it always!

I thought, disconnect the hose at the slave and on the opposite side of the gear box, unclip from the top of the gearbox at the join and remove. Disconnecting the hose was simple, a tight squeeze under there, but simple enough.

So now I’m sitting with both end off and trying to “unclip” the top… Turns out it is not just clipped in there. It is held on by one of the gearbox mounting bolts!! This bolt is not accessible as is.

I had to drop the gearbox by undoing the rear mounting and then spent over an hour trying to fiddle and figure out how to get to that bolt. Eventually I realized the only way was to use 2 extension bars and go over the top of the gearbox with the ratchet next to the drive shaft at the rear of the gear box!! This involved also unclipping the gear selector rods so the ratchet had room to maneuver. After that it was off in a matter of minutes and I was able to send the old hose in to get a new one made up.

Reinstallation was reverse of removal, as it usually is ;-)

My next frustration was manually bleeding the clutch line! No matter how much my wife pumped the clutch pedal it seemed to never get pressure and air kept coming out. So, we gave up trying to do it that way and fetched a pressure bleeder from my uncle, the type you connect to a tyre. We made sure the tyre we used had only 1 Bar of pressure and bled the system with 5 minutes of connecting the pressure bleeder!! I have to get myself one now!.

So far the clutch is working as normal and there does not seem to be any more leaks.

I hope my experience helps someone else who wants to do this themselves save some frustration….

Cheers,
Jase

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