Clutch hydraulic line keeps blowing a hole in the center of the line?

Hello SHANE BETTERTON,

Sounds like something is binding at the transmission, possibly the slave cylinder itself.

How is it shifting?
Does the clutch slip?
Any chatter or shudder on clutch release?
Any pulsation in pedal or other vibrations?
Does the clutch stick?

Is this an aftermarket replacement part?

Most people have an issue with the line staying on, mostly from an aftermarket slave cylinder.

Sounds like the hose is the weak point. Maybe it is getting close to the exhaust?

Can you send an image of the damage to the line possibly?

Thank you,
Brendon

Hello SHANE BETTERTON,

What are you using for a replacement for the line? Is it a Ford Part or are you using an aftermarket part?

Also, take a look at the photo I have included. In it you will see the hydraulic line going to the slave cylinder. Do you line have this heat shield wrap on it?

If so, how far up does the wrap go?

Also, how are the cab mounts? If some are worn on that side it could cause the body to pinch the line on the frame as you drive it down the road, slowly causing damage until it breaks. I added some images of examples of a bad body mount. Since the vehicle is 20 years old, if they have never been replaced, they are probably worn enough so that when you sit in it and from the bouncing from going down the road, may be damaging the line.

You might want to have someone around your body weight sit in the truck and see if it sinks down, maybe have them bounce up and down while you are watching the space between the body and the frame.

How is the truck running? If it isn't running properly, for instance if it was burning more air than fuel, the catalytic converter and pipe will get much hotter and could be boiling the fluid, especially if you are using an open bottle of brake fluid. Since brake fluid will absorb water from the air. It will lower the boiling point of the fluid from 400 to about 280 degrees Fahrenheit. So, it is always important to use fresh, unopened brake fluid.

But even if it is boiling, I don't think it is going to burst that line, plus you would have issues with the clutch operation, like a spongy pedal.

It may be a combination of heat and damage causing it to burst.

The air bubbles might be from damage to the line or a leak somewhere in the system. It might be related, it might not.

If you could send me a photo of the damaged line as well, it will help me see what might be causing it to keep bursting.

Thank you,
Brendon