Hydraulic clutch failure - split plastic tubing

[ozactiva]

The hydraulic line on my clutch has a small split near the union to the slave cylinder. Any failure in the system is supposed to be replaced by a complete system (master cylinder, slave cylinder and connecting tubing). I have been told that this system costs over $1000, if I can find one. I think that the XM and C5 use a similar system. Whether it would be a suitable system is up for conjecture. Does anyone have a second hand system from any of these cars?

As an alternative, I am considering attempting to repair (bodge). The union to the slave cylinder consists of the plastic clutch line fitting over a barbed connector. I assume that in the factory the plastic pipe is heated and crimped to seal the connection and prevent. I am wondering whether fitting a small jubilee clip with plastic metal, self annealing tape or gasket silicone may do the job. Otherwise I may cut the tube after the split and remove the tubing on the fitting. Then I would attempt to refit the tubing over the fitting by heating the tubing and pushing it onto the fitting. I could use a jubilee clip over the point where the barb is on the fitting.

Which option do you think would have the best chance of success. Or is there an alternate fix that I haven't thought of?

[CitroJim]

They can be repaired and in fact on here there is a long thread detailing how to bleed the system and how to fit a bleed nipple to the slave cylinder..

I'll see if I can find it for you as it'll tell you all you need to know...

[CitroJim]

Here we are. this is the thread. Don't worry it speaks of the Xantia 110HDi and 2.1TD. they use exactly the same clutch..

Go thorough this, replace the pipe and all should be happy although I think you may not find a jubilee clip will hold pressure. A replacement copper pipe or rubber brake flexi pile may be needed.

Anyway, hope that linked thread helps...

[addo]

I had a quick look at this today; there should be plenty of local solutions by thinking outside the box.

[CitroJim]

thinking outside the box.

A very important ability when dealing with old Citroens I find

[addo]

It's quite a tidy car under the bonnet; sadly the red metallic is a bit knackered outside from the sun.

[CitroJim]

That all looks very clean down there Adam You never see a Pom Activa looking that clean...

[myglaren]

I bet that if Vince had one it would sparkle!

[ozactiva]

Yesterday I cut out the split section of the plastic tube close to the slave cylinder. I heated to tube, using a heat gun as suggested, and attempted to push the tube onto the barbed connector. I was not successful and only got the tube over the first barb. I think the problem was that I was getting the tube too hot and it was compressing as it was pushed over the barb.

I3, how did you determine hot much heat was required to soften the tube enough to allow it to be pushed over the barb? I used the hot setting on my heat gun. Should I have used the cooler setting to heat the tube more gradually?

As I see it any alternate setup is going to require inserting a fitting into the tube. Any Ideas? If I cant get the tube over the barbed fitting I may have to resort to buying a complete new sealed system.

[MJM]

Try different heat levels. As you've found out, too hot and the tube reeves up. You may find that boiling water is hot enough. It's very much a suck it and see. We used to use a tube insert made by a company called Drallim, if I remember correctly. There may be a copper/steel tube with the right diameter to fit inside the plastic tube.