Anyone know how to get the PV 544 brake fluid reservoir hooked up without leaking? Up top on the firewall where the reservoir sits I can't get the small 5/16" I.D. tubing connecting the end of the metal brake line from the master cylinder to the bottom of the reservoir, leak free. The clamp holding the 5/16" I.D. tubing to the bottom of the reservoir works fine with no leaks. But I can't get the hose clamp holding the lower end of the tubing to the 1/8" metal brake line to secure evenly and apparently tightly enough to prevent leakage from this connection. Apparently the clamp will not bring the 5/16" tubing down far enough, or uniformly enough, onto the brake line to keep it from leaking. I'm at my wits end here trying to figure out a solution. Any ideas, guys??

Hello,

May I assume you don't have the special hose Volvo used?

The special hose does not require hose clamps, but does require that the metal brake line has an inverted flare on the end to mate properly inside the special hose.

FYI, I have those hoses in stock.
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Eric
Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
Torrance, CA 90502
hiperformanceautoservice.com or oldvolvosonly.com

Eric, I only have the standard metal brake line with the double flare (not an inverted flare) and has a 3/8 x 24 fitting on the bottom connecting into the threaded hole in the top of the master cylinder cap, and snaking up to the reservoir with a double flare on that end. That 1/4" diameter double flare I'm finding is impossible to clamp a hose around without it leaking around the flare somehow.

I ask again, do you have the special hose on your brake fluid reservoir?

The special hose has a 5/16" hole on 1 end to fit over the hose barb on the reservoir and the other end has a much smaller hole to fit on the inverted flare end of the metal brake line.

And when used, the special hose won't need any hose clamps on either end!!

If you bought a new reservoir from an aftermarket source, the hose that is included isn't the special hose Volvo used.

FYI, inverted flare is another name for a double flare.
--
Eric
Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
Torrance, CA 90502
hiperformanceautoservice.com or oldvolvosonly.com

Jumping in here with a related thought on a “leaky” brake fluid reservoir on my 1962 PV.
Using the proper hose (sourced from Eric) and reassembled after completing a complete flush of all fluid and cleaning the reservoir, I had a very slight leak running down that brake line on to the master cylinder.
It drove me nuts for most of a day until I noticed by shining a light through the reservoir I could see a couple tiny hairline cracks in the plastic of the reservoir, right under the metal band that secures it.
Loosened the bolt that secures that band just slightly, enough to hold the reservoir but not so tight that it squeezed the reservoir excessively, and my leak was gone.
The over-tight mount was squeezing things just enough to cause fluid to weep out of those tiny, almost invisible hairline cracks, and it seeped down and it collected there at the little tube and then ran down the metal line, so it had the effect of looking like the leak was there at the tube.