#5 Injection Hard Line for '84 D24
 

My #5 Hard/Injection Line is leaking again....

Is this a design flaw on this line?
All the others are fine and I've already replaced #5....
I put epoxy on the line, but that only slowed down the leak a bit.

Anyway, looking for another used #5 line in good shape or a new line if possible (Does anyone know a place that can bend a new line?)

The reason they break is because the anti-rattle clips are missing. Folks often discard them but they serve an important purpose, the lines will keep cracking and/or chafing without the clamps in place. No design flaw when the clamps are used but without them, #5 and #6 do seem to be the ones that fail most often, for whatever reason.

I've got a few sets for D24T but can't remember if the #5 line is different, I know #6 is -- hoping to not break up my sets anyway. Last I checked Volvo still sold new single lines pretty cheaply, and they sell the anti-rattle clamps too. Might be your best option. Alternatively you can pillage the 4-line and 2-line clamps from a junkyard VW, but the 6-line clamp near the vac pump is unique to D24. You'll want to have all of them to avoid ongoing problems.

Maybe I can secure all the lines with rubber innertube....

How do I go about getting a new injection line from Volvo?
Do you have a number/website or email I can contact?

If anyone has a #5 injection line they want to part with, let me know.

You mean as cushioning when the rubber is missing from the metal clamp? That is what I am doing on a few of mine and it seems to be working. Substituted pieces of rubber innertube for the original cushions.

Or are your metal clamps missing?

Yeah, looks like that's what I'm going to have to do in the meantime.