Clutch Hydraulic System: Service and Repair

STANDARD PROCEDURE - BLEED CLUTCH

Special Tool

Line Disconnect Tool 6638:

To determine if the master cylinder assembly requires bleeding or if the complete system requires bleeding:

1. Uncouple the clutch cylinder line from the clutch slave cylinder with quick Disconnect Tool 6638.

2. Slowly depress the clutch pedal.

CAUTION: Do not apply too much force as this will cause the uncoupled male coupling to blow out.

3. If the pedal feels hard in a relatively short distance, air is present in the clutch slave cylinder.

4. If the pedal feels spongy air is present in the master cylinder assembly.

LINKAGE BLEED

Hydraulic Clutch Reservoir:

1. Remove the reservoir cap taking care not to damage the diaphragm. If fluid level is not up to the step in the reservoir add D.O.T. 4 brake fluid.

CAUTION: Use only D.O.T. 4 compatible brake fluid. Other than D.O.T. 4 will cause system malfunction.

Release Bearing/Hydraulic Slave Cylinder:

2. Slowly depressing the clutch pedal while opening the clutch slave cylinder bleed screw.

3. Holding down the clutch pedal and tighten bleed screw to 15-20 Nm (11-14 ft. lbs).

4. Repeat Step 2 and Step 3 two times then check fluid level in reservoir.

5. Pump clutch pedal rapidly a minimum of 10 times. If clutch pedal still feels spongy, repeat Step 2 through Step 5.

MASTER CYLINDER BLEED

1. Uncouple the master cylinder line from the clutch slave cylinder, with quick Disconnect Tool 6638.

2. Remove the reservoir cap taking care not to damage the diaphragm. If the fluid level is not up to the step in the reservoir, add D.O.T. 4 brake fluid.

CAUTION: Use only D.O.T. 4 compatible brake fluid. Other than D.O.T. 4 will cause system malfunction.

3. Open the male quick connect coupling by depressing the poppet in the coupling while depress the clutch pedal to the floor.

4. Close the quick connect coupling by releasing the poppet while holding the clutch pedal to the floor.

5. Release the pedal.

6. Repeat Step 3 through Step 5 two more times and check fluid level.

7. Couple system back together. Then pump clutch pedal rapidly a minimum of 10 times.

8. If clutch pedal still feels spongy, repeat.