The hydraulic clutch control system consists of the hydraulic master cylinder, slave cylinder, reservoir, clutch pedal position switch, and connecting hydraulic lines. The clutch disc and pressure plate are single-disc type. The clutch release bearing or bearing arm is activated by hydraulic pressure. The clutch linkage or pedal position requires no adjustments.
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.
HYDRAULIC SYSTEM BLEEDING
Internally Mounted (Concentric) Slave Cylinder
Using Disconnect Tool (T88T-70522-A), disconnect quick connect coupler. Clean area around reservoir cap. Fill reservoir with DOT 3 brake fluid. Using a small screwdriver, depress internal mechanism of male quick connect coupling to open valve. Slowly depress clutch pedal to floor and hold. Release internal mechanism of coupling to close valve. Repeat 4 times.
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.
CLUTCH MASTER CYLINDER & RESERVOIR
Prying retainer bushing and push rod off clutch pedal pin, disconnect master cylinder push rod from clutch pedal. Remove Clutch Pedal Position (CPP) switch. See CLUTCH PEDAL POSITION (CPP) SWITCH.
Remove clutch master cylinder reservoir. Raise and support vehicle. Disconnect clutch slave cylinder hydraulic line by pressing White retainer bushing with Disconnect Tool (T88T-70522-A) while pulling on line. See Fig. 3. Plug line to prevent leakage.
Disconnect line from mounting clips. Lower vehicle. Rotate master cylinder 45 degrees clockwise and remove clutch master cylinder.
Inspect master cylinder for weak spring, damage to reservoir components and damaged cups. Also check master cylinder for scored piston.
When installing NEW master cylinder, bench bleed master cylinder. See BENCH BLEEDING (MASTER CYLINDER) under BLEEDING HYDRAULIC SYSTEM. To install, reverse removal procedure. Clean all rubber parts with DOT 3 brake fluid. Replace clutch master cylinder push rod retainer bushing if worn or damaged.
Ensure retainer and push rod are installed on clutch pedal pin with flange portion of bushing facing away from pedal blade of clutch pedal. Bleed hydraulic system. See HYDRAULIC SYSTEM BLEEDING under BLEEDING HYDRAULIC SYSTEM. Depress clutch pedal at least 10 times to check for proper release and smooth operation.
INTERNAL (CONCENTRIC) CLUTCH SLAVE CYLINDER & RELEASE BEARING
CAUTION:Clutch release bearing is prelubed and should not be cleaned with solvent. Clutch release hub and bearing are replaced as an assembly. DO NOT disassemble for inspection or replacement.
Disconnect clutch slave cylinder hydraulic line by pressing White retainer bushing with Disconnect Tool (T88T-70522-A) while pulling on line. See Fig. 3. Plug line to prevent leakage. Raise and support vehicle. Remove transmission. See TRANSMISSION.
Remove 2 internal (concentric) clutch slave cylinder bolts. Remove concentric clutch. Push clutch release hub and bearing against spring. Remove retainer ring. Remove clutch release hub and bearing, and spring. See Fig. 5.
Check internal (concentric) clutch slave cylinder for leakage. Replace slave cylinder as necessary. Also check slave cylinder for weak spring, worn or damaged piston and worn or damaged boot. Rotate outer race while applying pressure. If bearing rotation is rough, replace clutch release hub and bearing. Check for any surface scoring or burrs that may impede sliding motion of clutch release hub and bearing.
Prior to installation, lubricate bearing bore and bearing carrier with multipurpose grease. On clutch release hub, polish any scoring or burrs with fine grade of emery paper. To complete installation, reverse removal procedure. Bleed hydraulic system. Refer to HYDRAULIC SYSTEM BLEEDING under BLEEDING HYDRAULIC SYSTEM. Tighten bolts to specification. Refer to TORQUE SPECIFICATIONS table.
Tuesday, November 25th, 2008 AT 5:44 AM