I'm several months into a 240D engine build and should be ready to crank the engine for the first time today.

In putting the clutch slave cylinder back on the tranny, the line cracked and broke where it comes out of the cab.

In trying to find a replacement line, I decided to use a new SAE brake line and reuse the old fittings. The line diameter is really close. I think I can cut it and bend it to shape and length, but what kind of flare is used?

45 degree?
37 degree?

__________________
Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

I do not know the numbers...
but for others seeing this later... is this a double flare like is used on steel brake lines ?
A special tool is needed for that....

I can't tell because the contact surface has been crushed, but it certainly could be now that I look at it. If it starts out like the rest of those metris euro lines it certainly doesn't look like that any more.

We'll see if we can't make something work. I have access to both a 37 and 45 degree flare tool, but nothing that will make the double flare.

__________________
Michael LaFleur

'05 E320 CDI - 86,000 miles
'86 300SDL - 360,000 miles
'85 300SD - 150,000 miles (sold)
'89 190D - 120,000 miles (sold)
'85 300SD - 317,000 miles (sold)
'98 ML320 - 270,000 miles (sold)
'75 300D - 170,000 miles (sold)
'83 Harley Davidson FLTC (Broken again) :-(
'61 Plymouth Valiant - 60k mikes
2004 Papillon (Oliver)
2005 Tzitzu (Griffon)
2009 Welsh Corgi (Buba)

Im pretty sure it is a double flare the same as brake lines. Look at the old one to see if it has 2 layers. You can buy a passable double flare maker at harbour freight pretty cheaply

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1982 300CD Turbo (Otis, "ups & downs") parts for sale
2003 TJ with Hemi (to go anywhere, quickly) sold
2001 Excursion Powerstroke (to go dependably)
1970 Mustang 428SCJ (to go fast)
1962 Corvette LS1 (to go in style)
2001 Schwinn Grape Krate 10spd (if all else fails)

If it's like the SLS line in my old 300D, it is 6mm if I recall correctly, and a 12mm nut. I think I got mine from Performance Tool and Supply (814-362-3221), and they had the flare tool, too. I am out of the country right now, but I have the kit at home if you can wait 'til January to do it. You are welcome to borrow it. I may have some 6mm line leftover, too.

I believe someone mentioned that www.swagelok.com makes splice kits, too.

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1992 300D 2.5T
1980 Euro 300D (sadly, sold)
1998 Jetta TDI, 132K "Rudy"
1974 Triumph TR6
1999 Saab 9-5 wagon (wife's)