defender 200 tdi clutch pipe problem

i'v replaced master and slave clutch cylinders on my defender 200tdi. Ihave also replaced the rubber pipe that connects to the slave. Noticed that there is a small leak where the metal pipe from the master attaches to the rubber pipe. I have tried tightening (with difficulty as space is limited and metric spanners dont fit!) it but still leaks underpressure. could it be that the flaring on the metal pipe is damaged or shall I try more tightening? If itv is damaged is it possible to re-flare? What size diameter is the pipe. Any suggestions?

Simba9 said:

i'v replaced master and slave clutch cylinders on my defender 200tdi. Ihave also replaced the rubber pipe that connects to the slave. Noticed that there is a small leak where the metal pipe from the master attaches to the rubber pipe. I have tried tightening (with difficulty as space is limited and metric spanners dont fit!) it but still leaks underpressure. could it be that the flaring on the metal pipe is damaged or shall I try more tightening? If itv is damaged is it possible to re-flare? What size diameter is the pipe. Any suggestions?

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Sounds like the flare is damaged or has dirt in it that is preventing a proper seal. It's a steel pipe which isn't the easiest to flare unless you have a decent pipe flaring tool. I would first take it apart and check that it is clean then try and re tighten. If you don't have the right spanners then it will make it a load more difficult so get the right ones first. Or buy some copper brake pipe with a couple of ends ( most auto shops will sell) and make a new pipe up using a flaring tool. Making a new pipe is easy and on e you get the hang of flaring should only take 20 mins. While your there check your brake pipes if they are the original steel ones I imagine the are probably on there way out so the new pipe / flaring tool option might be best if you need to replace them as well.

copper is fine for clutch pipes ,but it is 1/4 rather than 3/16 as brake pipe is

Thats useful to know. i assume the unions are a non metric thread and I'll have to get a couple of those. is the thread on on those 7/16 unf or is it 9/16? and is the thread the same at both ends but different gender.

Thanks for the information. I'll buy some 1/4 copper pipe from ebay but I cant seem to find any unions with a 9/16 unf thread. Any one know a supplier/seller

Take the pipe to lacal motor spares place and get them to make you a new pipe up, cost me about £3

ive got this problem on my discovery and i can't seem to find unions for it either but mine have a 1/2 hex head and 1/4 bore hole but the thread is course and no onw where i am stocks them but just fine thread