I recently overhauled the clutch master cylinder, but now I can't get the supply hose back in place. The hose is too short to extend out to a comfortable length to insert into the cylinder. This means that the cylinder and brake pedal assy needs to be in place when the hose is fitted. I was told that it is easier to fit the hose by first inserting the plastic coupling into the cylinder and then inserting the pipe over the coupling.

This made sense, but I can't remove the plastic coupling from the supply hose without damaging it. I have even cut some of the firewall rubber away to try and improve my hold on the pipe, but that still wasn't enough. Can somebody having done this please tell me how they got the supply hose back in the cylinder?

Are you referring to the hose that goes between the reservoir and the master cylinder. If so that hose should be 270MM long, the MB part number is 203 997 31 82.

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'86 300E 5 speed
'71 Triumph TR6
'46 Cushman Scooter
'41 Ford 9N tractor

Ok, but with the cylinder in place how do you get the supply hose back in the cylinder? There isnt enough space to grip the pipe to push it in.

I just took a look on my car and its tight up there. Forgive me if you tried this already but it appears the best way would be to remove the clutch master cylinder. Attach the coupler and hose to the master cylinder and feed the hose through the opening/rubber boot. Maybe a helper can pull on the hose as you get the cylinder in the right spot to reinstall.

Thats the best I can do as I never had to remove the master cylinder.

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'86 300E 5 speed
'71 Triumph TR6
'46 Cushman Scooter
'41 Ford 9N tractor

another possibility is to disconnect hose from the reservoir to give you some slack to allow connection at the cylinder. Once connected, pull up and reconnect at the reservoir where your fingers can get at it. If I were doing it and remembered to order a new hose that would be replaced as I wouldn't want to go back in there again. The hoses get kind of "worn" where they attach.

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Hanno
'79 6.9 Sold (after 27 years)
'83 280SL, 5 spd.
'94 E320 Sdn. 5 spd conversion
'02 E320 Sdn.(on loan to mom!)
'87 300E (5 spd. conversion) Sold
'05 E500 Wagon

Ok thanks. Ordered new pipe yesterday. As far as i could see you need to remove the brake master cylinder to remove the pipe, and will then have to bleed the entire brake system aswell. I assumed this because i cant see the supply hose connect to the fluid supply. Will take another look today.
Ps. If you have never removed the clutch mc and need to do so, dont! This is the type of thing you pay someone else to do.