BLEEDING HYDRAULIC SYSTEM
BENCH BLEEDING (MASTER CYLINDER)
With reservoir and hydraulic line attached to master cylinder, lightly clamp reservoir in a vise. Fill reservoir. Hold master cylinder vertically below reservoir. Ensure clutch line quick connect is below master cylinder. Using a small screwdriver, depress internal mechanism of male quick connect coupling to open valve. Pump and hold master cylinder push rod. Close quick connect valve. Release master cylinder push rod. Fill reservoir. Repeat this step 9 times.
With master cylinder in same position and quick connector closed, pump master cylinder several times quickly to expel any remaining air. Then, using fingers, pinch reservoir supply hose 2 or 3 times to help move air into reservoir. Check push rod stroke length. If stroke is.160" (4 mm) or less, reinstall clutch master cylinder. If push rod stroke length is not as specified repeat bench bleeding procedure.
HYDRAULIC SYSTEM BLEEDING
Externally Mounted Slave Cylinder
If bleeding new (dry) replacement master cylinder, bench bleed master cylinder first. See BENCH BLEEDING (MASTER CYLINDER). Remove slave cylinder from transmission bellhousing. Using a 3/32" diameter punch, remove pin that holds hydraulic line in slave cylinder. Remove hydraulic line from slave cylinder. Place end of hydraulic line into container.
Hold slave cylinder so hydraulic line port is at highest point. Fill slave cylinder through hydraulic line port with DOT 3 brake fluid. Gently push on slave cylinder push rod to expel all air.
When all air has been expelled, install slave cylinder. Remove clutch master cylinder reservoir cap and diaphragm. While maintaining fluid level in reservoir, observe hydraulic line until all air has been expelled, a steady stream of fluid is flowing, and fluid is level with step in clutch master cylinder reservoir.
Install reservoir cap and diaphragm. Install hydraulic line and retaining pin. Remove slave cylinder. Ensure reservoir is full. Hold slave cylinder so hydraulic line port is at highest point. Slowly push pushrod into cylinder and let it return. Repeat 2 more times. Install slave cylinder.
Rapidly depress clutch pedal 10 times. Top off with brake fluid. With transmission in Neutral and parking brake set, start vehicle. Shift vehicle into Reverse. If gears grind, check for air in system. Repeat bleeding procedure if necessary. If no air is found and gears grind, clutch components may be defective or worn out.
Internally Mounted (Concentric) Slave Cylinder
Using Disconnect Tool (T88T-70522-A), disconnect coupling at transmission by lightly tugging on clutch tube while sliding White plastic sleeve toward slave cylinder. See Fig. 7. Clean area around reservoir cap. Fill reservoir with DOT 3 brake fluid. Using hand pressure, apply 10-15 lbs. (4.5-6.8 kg) to clutch pedal. If pedal is hard and moves 0.25-0.50" (6-13 mm), go to step 3). If pedal is spongy, go to next step.
Using a screwdriver, open valve of male coupling. Slowly depress clutch pedal to floor and hold. Remove screwdriver to close valve, and release clutch pedal. Ensuring reservoir is full, repeat this step. If pedal is no longer spongy, go to next step.
Close reservoir and reconnect coupling. Rapidly depress clutch pedal 5-10 times and wait 1-3 minutes. Repeat this step 3 more times. Place hose on bleeder screw to prevent brake fluid from entering bellhousing. Loosen bleeder screw.
Place light pressure on clutch pedal and open bleeder screw. Maintain pressure until pedal contacts floor. Close bleeder screw while pedal is fully depressed. DO NOT allow pedal to return before bleeder screw is fully closed. Recheck fluid level. Apply 27-44 lbs. (12-20 kg) of pressure to clutch pedal while tightening bleed screw.
Test system operation by starting vehicle, depressing clutch and placing gearshift in Reverse. Depress clutch pedal to within 1/2" (13 mm) of floor. If grinding noise is heard, check for air in system. Repeat bleeding procedure if necessary.
Thursday, November 27th, 2008 AT 9:32 PM