997 Clutch cylinder above gearbox - Pipe union

kalsi997 · Mar 13, 2020

Hi all,
I thought I would flush out the clutch/brake fluid from my clutch pipes after giving all the brake callipers a full refurb including seals. The awkward location of this clutch master cylinder makes it a real pig of a job. Anyway after considerable perseverance I managed to flush out all the old clutch lines which was a very dark colour, so a good thing I managed to replace it. I also noticed the coiled pipe from the clutch cylinder attached to the brass union / blue pipe was also very corroded, so I ordered a new pipe from OPC to be replaced by myself before summer.
My problem is that the brass union joining this coiled pipe to the blue clutch pipe is extremely tight and has to be undone from one end before it can be removed. One end has unfortunetely been rounded off as this pipe is incredibly tight and it looks like I will have to replace the brass union. Has anyone else ever had a similar problem before? Any advise will be appreciated. I have attached a photo showing the brass union joiner and blue clutch pipe.

Thanks all.

Lancerlot · Mar 13, 2020

You'll probably need a flare-nut spanner rather than the usual open-end type and, being brass, the fitting might well respond if you warm it with a hot air gun.
Regards,

Clive

ScotDoc · Apr 2, 2020

Not sure where it’s corroded in that photo. Does it really need to be replaced? If so, as Clive says, flare nut spanner (or a high quality crow’s foot spanner and get a 3/8" extension onto it. I have a very high quality Snap-On one which I reserve for such difficult jobs. Risky though as brass is soft and looks like flats are already starting to round off a bit.

That rotating joint was very stiff when I installed new slave cylinder on my 997TT. Squirt of WD40 made it spin much better when screwing brass union into slave.

kalsi997 · Apr 3, 2020

Thanks all for your assistance. Unfortunately the brass nut is totally screwed. My only option left now is to replace the brass nut or to replace the blue pipe along with a new nut. The price difference for the two is only a few pounds. I am leaning towards the nut only assuming I can get it off without damaging the blue pipe. Any further advise please?

Lancerlot · Apr 3, 2020

I'm unfamiliar with this set up, but from the photo it looks as though the blue nylon hose is a push fit into the flare nut and should be capable of being released by pushing down on the nut's centre ring. But apologies if I've misinterpreted this fitting.

An alternative would be to slice through the nylon hose and thread on a new nut and/or olive as required.
Regrads,

Clive