Clutch defect in the Honda Jazz GD?

Solution with Epytec SF1 steel braided hose – clutch damper permanently removed

Introduction & aim of the conversion

A total clutch failure is always annoying – especially when the cause turns out to be an original part that is no longer available. This is exactly what happened with the Honda Jazz GD (built in 2004, 1.2 DSI engine): the clutch pedal suddenly dropped without warning. Diagnosis: The factory-fitted clutch damper – a comfort solution for smoother gear changes – had a fine hairline crack and was leaking hydraulic fluid. This rendered the clutch completely inoperable.

The solution: complete removal of the defective clutch damper and conversion to a continuous Epytec SF1 steel braided hose – custom-made using our configurator. This not only saves money, but also noticeably improves the clutch feel.

Technical details of the upgrade

Honda uses a two-piece line design with an intermediate damper in certain GD models ex works. This is located between the master and slave cylinders and has an internal diaphragm for pressure modulation. Over the years, however, this component tends to crack and leak.

The chosen conversion replaces this entire system with a continuous steel flex line, manufactured according to customer specifications:

• Length: approx. 50 cm (Note: 40 cm would be more ideal, but 50 cm is perfectly usable)

• connection 1: M12x1 external thread, suitable for the clutch master cylinder

• connection 2: M10x1 internal thread, for connection to the rigid line towards the slave cylinder

• Stainless steel sheathing, with TÜV-approved hose material and material certificate

The custom-made steel braided hose made it possible to completely replace the original Honda hose configuration (unfortunately, the OE number of the affected components is no longer available as they are no longer listed in the parts catalogue).

SF1 Configurator

IIn this case, variant 1 was used. The customer used the Epytec steel braided hose configurator at https://epytec.de/uk/steel-brake-line-steel-brake-line-custom-configurator-sf1

Thanks to the clear selection options (length, connections, thread types), no drawing was necessary. The price was displayed immediately, and the pipe was produced and delivered quickly – naturally with a material certificate for possible individual acceptance.

TÜV & Approval

As the Epytec SF1 cable is a custom-made product, a parts certificate is included. Individual approval in accordance with §19 StVZO (German Road Traffic Licensing Regulations) by TÜV SÜD or DEKRA is possible.

In the case of safety-related modifications – such as to the clutch's hydraulic system – we recommend having the conversion documented.

Conclusion & customer value

The conversion demonstrates how practical and flexible our custom-made products with steel braided hoses are – even in unusual applications such as the hydraulic system of a clutch.

Instead of searching for overpriced or no longer available OEM components, this offers a durable and high-quality solution. Direct replacement saves space and weight and even improves clutch feedback.

🔗 Now configure your SF1 line individually

FAQ

Question 1: How durable is the engine mount under load? 

Our brackets are made of high-strength steel and are designed for standard and performance-enhanced engines. The material certificate proves their load-bearing capacity – even at high torques, for example in the OM606 biturbo conversion. 

Question 2: Is it possible to register with the TÜV? 

Yes, registration is possible without any problems via individual approval. We will provide you with a material certificate to submit to the TÜV – ideally in combination with a test report or proof of conversion. 

Question 3: Can I reverse the conversion? 

Yes, as the engine mount is designed to fit the original mounting points, it can be removed and replaced with a standard gearbox without any permanent modifications. 

Question 4: What tools are required for assembly? 

Standard tools are sufficient. An external hexagon bit (e.g. E10 or E12) is important, as Mercedes uses this design for its OE screws. A gearbox jack makes installation much easier.

Click here to go directly to the configurator

We can also help you find your individual solution.

Would you also like a tuning conversion or a special solution for your vehicle, just like this customer? Simply get in touch using our contact form. With over 15 years of experience, we can carry out your conversion quickly and cost-effectively.

Would you like the same wiring configuration for your vehicle (e.g. Honda Jazz GD 1.2 DSI)? Then send us a message via the contact form with reference to this conversion report. We will prepare an individual quote for you.

About Epytec

Epytec is a specialist in the manufacture of tuning adapters and special cables – with over 15 years of experience. Our products, manufactured in Germany, stand for quality and innovation.

Tuning adapters and steel braided lines connect components from different vehicles – with a perfect fit and TÜV approval. Whether for motorsport or everyday use: our solutions are customised, durable and tried and tested.

Our commitment to the highest quality and customer satisfaction guarantees hassle-free TÜV registration. This makes Epytec the market leader for hobby tuners and professionals alike. With Epytec, you are choosing technology that is "Made in Germany".