While doing my valve adjustments and diesel purge today on my '82 240D (4 speed), I noticed something amiss:

A braided hose (circled in red) leading from my brake fluid reservior and into the firewall was seriously deteriorating and weeping brake fluid, with the fluid building up on top of the inside fender well.

I wiped off the hose before taking the car on a short test drive around the block. During that short run, the hose had already started to get soaked again with brake fluid.

In the interest of safety, I have parked the car for now, until I can fix whatever is causing this.

Questions:

1) Where does this hose lead to? It looks to me like it goes inside and under the dash. Why would that be?

2) Can/should I replace it with something better than braided fabric?

3) Also, the nipple that the hose fits onto on the brake fluid reserviour seems rather short, and there's no hose clamp. The hose is very frayed where it goes over that nipple. Should there be a hose clamp there?

Thanks,

- Patrick

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1982 240D. 198k, Marine Blue/Blue, 4 Speed, Crank Windows, No Sunroof, No Rust, No Oil Leaks
2001 TDI. 197k, Lagoon Blue/Black, 5 speed, Chip, G60/VR6

my guess is its for the clutch. my sd is an auto and it has that nipple sticking off but no hose. the clutch is my best guess

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have no worries.....President Obama swears "If you like your gun, you can keep it

Yes that hose is for the clutch. MB has started making those braided hoses out of a really durable rubber hosing when you go and get OEM replacements, I found this out when I got new fuel hosing from the dealer, the old braided stuff has been superceeded with a thick strong rubber hose.

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-diesel is not just a fuel, its a way of life-
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'13 ML350 Bluetec - 95k - dad's (OC-98k)
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Looks like some blue VW master clyinder resivour tube would probably work.

The PROPER hose is press fit and thus you don't need a clamp. There is a barb on the end of that nipple that holds things on very well. After you put your new hose on, try to pull it off. Assuming it is the right stuff and has a cloth-like outer covering, you won't get it off.

And yes it goes to the clutch...found this one out a couple days ago

I'm afraid it failed due to old age. You are going to have to replace it every 20 or 25 years from now on.

The original hose has a woven covering that acts like a chinese finger trap and needs no clamp. You could substitute neoprene fuel line or clear plastic. The clear line doesn't need a clamp as a rule, but if you want to put one on, small plastic tie wraps work well for mini hose clamps.

While you are under the hood, check all your fuel lines, radiator hoses, heater hoses etc. If they are mummified and hard, or soft mushy and swollen it would be a good idea to replace them now before you get stranded on the road. Like I say, this is normal maintenance and will need to be done every 20 or 25 years.

The plastic nipple that the hose fits over is not very strong, especially after 20 years. Therefore, be extra careful when removing the old hose. If it fights you, you may want to consider cutting it away from the nipple.

If you make an error in judgment here, you are looking at a new reservoir.

I once did this with a heater core. The hose decided to be a giant PITA. I, being the stronger of the two of us, won the argument. The copper pipe nipple that extended into the heater core did not.

I, too have the same leaky braided hose. I go through bottles of Dot-4! The clutch goes to the floor about once evey other week, now. I have cut the hose back twice now, and don't have any more slack. I will buy the new rubber hose. Two things still puzzle me..... If this is the is the culprit, where is all the brake fluid? It's not on the garage floor. It's not on, or under the carpet by the master cylinder. And why is the clutch getting air the lines, anyway, if the leak is up above the master cylinder? The hose should still have fluid in it going down to the master. I can't find any other leaks from the master to the slave. Could there also be a leak at the slave going into the bellhousing?

The panel under the dash has a felt pad glued to it for noise buffering, often when something under the dash leaks, ign sw (from bad shutoff) oil gauge, or clutch cyl, the pad soaks it all up until its saturated and then it begins to drip out into your carpeting. You can carefully remove the panel, I would pull the carpets first just in case, get it out then turn it upside down and rinse it out good then let it dry outside in the sun. Oil is a bit more difficult to get out.

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Chris
64 190D R.I.P.
80 240D W/617 engine -for sale
82 240D -for sale

Same hose problem here as well. I looked on the parts index and could not find one listed. Anyone got a part # for a 79 240D?

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79 240D (no name yet) 203K Miles Maple Yellow
98 2500 4x4 HD Dodge 24 Valve Cummins TD
83 Chevy Van (Dead-Trans. shot)