Clutch hydraulic line keeps popping off slave cylinder?

KFOOKS

MEMBER
1999 FORD F-150
4.2L
6 CYL
2WD
MANUAL
400,000 MILES

It had a leak in a hose that caused the truck to start overheating. While fixing that (I know one has nothing to do with the other. Just bad timing) we lost our clutch. No resistance whatsoever. Tried bleeding it but we couldn't get anything to come out and brake fluid in reservoir was staying full. So, we got a new clutch master cylinder thinking it wasn't pushing the fluid to the slave. When trying to install the new clutch master we cannot get the hydraulic line from the master to the slave to stay on. Every time we press the clutch, it pops off. We have bled the system and it still pops off. We even went and got a new hydraulic line, and it still pops off. We're out of ideas.

2 Replies

MIKE H R

MECHANIC
3,094 POSTS

On the lines should clip on with a plastic retainer that keeps the line on. If not on all the way, it would pop off similar to what you say is happening. There is a special tool that you can use or a screwdriver to help it clip on.

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Tuesday, March 14th, 2023 AT 8:06 AM

BRENDON S

MECHANIC
653 POSTS

Good morning, KFOOKS,

Where is the line blowing off is it at the slave cylinder or at the master?

I would remove the master from the vehicle and bench bleed it. Then re-install and gravity bleed the system. Because of the position of the master, it cannot be bled fully while it is installed in the vehicle.

Looks like the line needs to have a roll pin installed to hold the line on the Master. Did your new line come with a new roll pin?

I am adding a video on how to bleed the system completely to rule out any air in the system.

https://youtu.be/s6cVYgzCU18

I have also added some pictures and procedures for your reference.

Please try these few things and let me know how it goes.

Thank you,
Brendon
2CarPros

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