Clutch: Service and Repair

NOTE: After a clutch hydraulic system has been removed from a vehicle and installed, or if air is trapped in the line, the clutch hydraulic system must be bled. The following procedure is used with the hydraulic system installed on the vehicle. The largest portion of the filling is carried out by gravity.

1. Clean dirt and grease from around the cap.
2. Remove cap and diaphragm and fill reservoir to the top with approved brake fluid only (brake fluid must be certified to DOT 3 Specification).

NOTE: To keep brake fluid from entering the clutch housing, route a suitable rubber tube of appropriate inside diameter from the bleed screw to a container.

3. Loosen bleed screw (located in the slave cylinder body) next to the inlet connection.
4. Fluid will now begin to flow from the master cylinder, down the red tube and into the slave cylinder.

NOTE: The reservoir must be kept full at all times to ensure that there will be no additional Introduction of air Into the system.

5. It should be noted at this point, that bubbles will appear at the bleed screw outlet. This means that air is being expelled. When the slave cylinder is full, a steady stream of fluid will come from the slave cylinder outlet. Tighten the bleed screw.
6. Place the diaphragm and cap on the reservoir. The fluid in the reservoir should be level with the step.
7. Exert a light load to the clutch pedal and slightly loosen the bleed screw. Maintain pressure until the pedal touches the floor. Tighten bleed screw (do not allow clutch pedal to return until the bleed screw has been tightened; and allow clutch pedal to return. Fluid and and air that is left will be expelled through the bleed port.
8. Refill reservoir to level at step. Install diaphragm and cap. If evidence of air still exists repeat steps 7 and 8.
9. Have an assistant actuate the clutch pedal slowly. Check for air in the red tube. If air is found, tap on the tube to encourage it to flow to the master cylinder. After the air has reached the master cylinder, it will flow into the reservoir.
10. The hydraulic system should now be fully bled and should properly release the clutch. Check the vehicle by starting, pushing the clutch pedal to the floor and placing the shift lever in REVERSE. There should be no grating of gears with the clutch pedal within 12.70 mm (0.50 inch). If there is, inspect the hydraulic system for air. Repeat bleed procedure from step 7.