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clutch hydraulic line leaking, cant separate the lines

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Hi all, a section of the blue hydraulic line between the master and slave cylinder has developed a leak, and i cant operate my clutch. the clutch itself just goes straight to the floor, and doesnt spring back. there is a small puddle directly under a flat spot in the tubing, it looks like something flattened the tubing and that caused it to weaken and blow out the side. anyhow, i have the replacement tube (part number oem-996-423-10910, number 9 on the diagram below). the car is an '02 C4S. i found a few threads relating to being able to get the thing apart

threaded joint disassembled

how do i get this thing disassembled (number 12 on the digram)? i cant replace the broken pipe till i get these couplings apart. is there a special tool? i tried turning both nuts in opposite directions, and i ened up round the corners on the nut a bit. i dont see any markings on the new or old joint that indicate an alignment that would allow them to slip off. i see the circlip inside the new tube, i understand how it works, but i cant apply enough force to get the male end to slide out from the circlip. i tried prying them slightly, but ended up just bending the tubing a bit. it sees obvious from that thread that i just need to turn the nuts in two different directions, but i cant imagine it should be as hard as i twisted? do i have to break the circlip? heat it? PB blaster (i dont imagine pb blaster and brake fluid play nicely...), the joint costs $118 at pelican, i dont want to break the thing unnecessarily, especially as the tube costs less than that joint.

any and all advice is greatly appreciated, i desperately need to get this resolved.


post-39974-092191100 1286205828_thumb.jp

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Please excuse my inexperience, i didnt (i dont even have any). but if thats what it takes, ill pick some up tonight. could you provide some insight into the assembly/disassembly process? loosen part A in the digram, slide the off the male end, slide A and the circlip on the new male piece and tighten? loctite on anything? any recommendations on dealing with the end of the hose that is near the strut?

Thanks again!

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before i put this post up, i called my local Porsche dealership, to inquire about what it would cost to have them perform the service. they said it is recommended that all the hoses in the system be replaced, as the connectors get damaged when removing them or something to that effect. any truth to this? i can see how uncoupling these joints (if done properly) could hurt anything...

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  • 9 months later...

I have a 98' boxster, and after a similar failure to the line and only replacing the line, a year later the coupling failed, and then the line behind the coupling, so there might be truth to what they say. I ended up having everything replaced from the slave to the master and it works like a charm now.

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