Last weekend I attempted to replace the clutch master cylinder in my 2003 Volkswagen Jetta Wagon TDI.  After lying upside down and inside out of the driver's side footwell for about a half an hour getting the master cylinder in, I was ready to connect the hydraulic lines.  I got my lines connected, and my assistant into the car to start bleeding the clutch system.  That went okay for about 3 seconds, until fluid started running out of the connector.  After taking it out and putting it back in a couple times, examining it thoroughly, the only thing I could do is scratch my head.  I appeal to anyone who can help me.

Here is a picture (below) of the slave side of the hose.  Two thumbs up for the German engineering here.  It's made of solid metal, has an o-ring to seal it, and a simple clip to hold it into place.  (Click on any of the pictures to see a much larger version.)


Moving on to the problem side... Below is a picture of the plastic clip removed from the metal line.  As you can see, the o-ring prevents fluid from leaking between the M/C housing and the plastic clip.  Okay, now here's where things get real foggy, really damn quick.  What keeps fluid from leaking between the metal line and the plastic clip?  According to the parts guy at the Spokane VW dealer, I am not missing any parts.


Below is a another picture of the clip installed onto the line

What am I not getting?  Nothing appears to be broken, the design seems to be flawed, and I fail to see how it could have ever worked.  I tried connecting the end back to the factory M/C, and it also now leaks.