Clutch Hydraulic System: Service and Repair

Hydraulic Clutch System Bleeding

Procedure
Warning: Refer to Brake Fluid Irritant Warning Brake Fluid Irritant Warning.


Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution Brake Fluid Effects on Paint and Electrical Components Caution.

Note: Only use brake fluid DOT 3. The hydraulic clutch actuation must now only be bled from "below", i.e. from the bleeder valve. A brake bleeder must be used for this purpose - see " Workshop Equipment" catalogue. Manual bleeding is no longer permissible. Observe manufacturer's instructions before using brake bleeder. The brake bleeder must be set to an operating pressure of approximately 2 bar.




1. Attach brake bleeder.

* Screw adapter (1) for corresponding brake bleeder onto brake fluid reservoir.

Note: Insert hose end in suitable brake fluid collecting basin.

* Disconnect valve cap from bleeder valve.
* Connect bleeder hose (2) to bleeder valve (3).

2. Bleed clutch.

* Switch on brake bleeder.
* Open bleeder valve 2-3 turns.
* Bleed until brake fluid escapes without bubbles at hose.
* Close bleeder valve hand tight.

3. Detach brake bleeder.

* Detach adapter from brake fluid reservoir.
* Push valve cap onto bleeder valve to protect the bleeder valve.

Note: The following operational stages must be undertaken to fill the pressure line between the transmission housing and the central release. When bleeding, ensure that the brake fluid reservoir is always filled up sufficiently and does not run dry.

4. Bleed pressure line between transmission housing and central release.

* Press and hold clutch pedal.
* Open bleeder valve until air or air/brake fluid mixture emerges.
* Close bleeder valve hand tight.

Note: Do not close the bleeder valve too fast.

* Release clutch pedal as far as the stop at normal speed.
* Wait approximately 5 seconds.
* Repeat this bleeding process 4 times.
* Tighten bleeder valve.
* Detach bleeder hose.
* Push valve cap on to bleeder valve to protect the bleeder valve.

5. Connect bleeder hose to bleeder valve, place free end in a suitable connecting container.
6. Top up brake fluid reservoir.

* Fill brake fluid reservoir up to "MAX" marking.
* Install brake fluid reservoir.

7. Check actuation pressure of clutch pedal.
8. Check shifting for ease of movement with vehicle stationary, with engine running and with clutch disengaged.
9. Road test the vehicle to ensure proper operation.
Undertake road test using varying RPM ranges and frequent gear changes, bring vehicle to operating temperature during this process. Ensure the brake and clutch system is operating correctly.