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Took me 3 hours to do the line replacement.
One hour of work
Two hours fighting the clips off, finally found the path of ease.
Two tricks
- You have to release the clips by removing them fully to remove brake line from the clutch master cylinder, the 135 degree angle fitting/bleed valve, and the pipe to the slave cylinder
- The master cylinder one can be done by mirror if your spatial relations are good, the easy way is to remove the ABS control module , then you get line of site. Clips can generally be reused, I had one rusty one. Part number above. You need three if replacing
- The fitting/slave is both blind and buried in the transmission, soooo….
Cut off the old clutch tube
Rotate the fitting 90 degrees
Voila! You can see the clip and remove easily. It helps to scrunch the top of the rubber gasket into the trans a bit to see as in picture
You reinstall by putting the clip in all the way, the pushing in the tapered o ring fitting until you hear the click!
The ugly – rusted out clutch line. The M8 bolts holding in the air cleaner and battery tray were nasty too.
You have to feed the clutch line through the air filter tray, so take a pic of the puzzle
I had to use a spiral cutter to get one of the M8s out, dropping down to the 11mm diameter one when the 13mm spun
You can just see the clip in the mirror buried under the booster and fuse boxes, If yoiur spatials are good you can get that with a pick but they do rust in place….in which case…
Another shot of the air filter box and clutch line – take a pic here first!!
Easy way – take your E5 and remove the ABS module
Now you have both line of sight and room for your hand and a pic and the clip pops out, and you dont lose it.
The clips look like this – my clip to the first stop on the black plastic adapter was so rusted in I never got it off, so I cut the old clutch hard line so that I could ….
Rotate the adapter clock wise 90 degrees to get to the clip
I invented and patented this trick, then read about it in the Volvo service instructions. My fame lasted 2 hours. Note the rubber bellows in scrunched into the tranmission housing just a bit, but the clip is easily accessed.
Off it comes with a tug..
You put the clips back in. all the way, the use the taper on the hard line to open and snap shut in the groove with an audible click.
I’m so smart for that rotation trick….of course if I had read the F* manual…..Volvo had already thought of that
I bled it for about three cycles, manually , without getting rid of air. I then read the manual and opened the bleeder one full turn and pushed 200 ml fluid. One more cycle of push, hold, crack, tighten, release and it’s working perfectly.
Job done.

