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Pinpoint Test C: Clutch Hydraulic System Check

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. C1 CHECK THE FLUID LEVEL 
      NOTE: Do not check the hydraulic system after the road test. Allow the vehicle to cool down before carrying out the clutch hydraulic system check.
    • Remove the clutch reservoir cap and clutch reservoir diaphragm.
      • Fig 1: Removing Clutch Reservoir Cap
      G03276090Courtesy of FORD MOTOR CO.
    • Check the fluid level of the clutch reservoir.
    • Is the fluid level at or above the step mark? 
    1. Yes  : INSTALL the clutch reservoir cap and diaphragm. GO to C2.
    2. No  : ADD brake fluid to the specified level. GO to C2.
  2. C2 INSPECT THE HYDRAULIC SYSTEM FOR LEAKAGE 
    • Check the reservoir and reservoir lines for leakage.
    • Check the master cylinder and hydraulic line for leakage.
    • Check the clutch slave cylinder and the hydraulic line connection for leakage.
    • Are there any signs of leakage? 
    1. Yes  : INSTALL new components as necessary. TEST the system for normal operation.
    2. No  : GO to C3.
  3. C3 CHECK INTERNAL OPERATION 
    • Remove the reservoir cap and reservoir diaphragm.
    • Have an assistant slowly depress and release the clutch pedal.
    • On the down stroke, the fluid level should not increase by more than 1 mm (0.039 in).
    • Does the fluid level increase more than 1 mm (0.039 in)? 
    1. Yes  : INSTALL a new cylinder master cylinder assembly.
    2. No  : GO to C4.
  4. C4 CHECK THE CLUTCH PEDAL RESERVE 
    NOTE: The clutch reserve is the distance between the clutch pedal when fully depressed and the position when the vehicle starts to move forward.
    • Park the vehicle on a level surface.
    • Check for obstructions behind clutch pedal.
    • Attach a cable tie to the lower clutch pedal.
      Fig 2: Attaching Cable Tie To Lower Clutch Pedal
      G03276091Courtesy of FORD MOTOR CO.
    • Attach a tape measure to the cable tie.
    • Depress the clutch fully and start the vehicle.
    • Shift the transmission into first gear.
      Fig 3: Shifting Transmission Into First Gear
      G03276092Courtesy of FORD MOTOR CO.
    • While observing the tape measure, slowly engage the clutch, noting when the vehicle starts to move forward.
      Fig 4: Measuring Pedal Travel For Clutch Engagement
      G03276093Courtesy of FORD MOTOR CO.
    • Is the clutch pedal reserve greater than or equal to 25 mm (1 in)? 
    1. Yes  : The clutch hydraulic system is OK. TEST the system for normal operation.
    2. No  : GO to C5.
  5. C5 CHECK THE CLUTCH SLAVE CYLINDER TRAVEL 
    NOTE: The clutch slave cylinder travel is the distance the bearing portion moves forward when the clutch is fully depressed.
    • With the vehicle in NEUTRAL, position on a hoist.
    • Remove the inspection plug.
      Fig 5: Removing Inspection Plug
      G03276094Courtesy of FORD MOTOR CO.
    • Using a wooden ruler, index-mark the rear of the bearing onto the ruler. Have an assistant fully depress the clutch pedal. Index-mark the rear of the bearing. Measure the distance between the two index marks.
      Fig 6: Index Marking Bearing
      G03276095Courtesy of FORD MOTOR CO.
      Fig 7: Measuring Distance Between Index Marks
      G03276096Courtesy of FORD MOTOR CO.
    • Is the clutch slave cylinder travel equal to 10.2 mm (0.4 in) ? 
    1. Yes  : GO to C6.
    2. No  : GO to C8.
  6. C6 CHECK THE CLUTCH PRESSURE PLATE 
    • Remove the clutch pressure plate. Refer to CLUTCH .
    • Inspect the clutch pressure plate for wear or runout. Refer to PRESSURE PLATE CHECK .
    • Are there any signs of excessive wear or runout to the clutch pressure plate? 
    1. Yes  : INSTALL a new clutch pressure plate. REFER to CLUTCH .
    2. No  : GO to C7.
  7. C7 INSPECT THE CLUTCH DISC 
    • Carry out the clutch DISC CHECK .
    • Is the clutch disc OK? 
    1. Yes  : GO to C8.
    2. No  : INSTALL a new clutch disc. REFER to CLUTCH . TEST the system for normal operation.
  8. C8 CHECK CLUTCH PEDAL FREE PLAY 
    NOTE: The clutch pedal free play is the distance between the clutch pedal when fully released and the position when slight resistance is felt on downward motion.
    • Engine OFF.
    • Attach a tape measure to the cable tie.
    • While observing the tape measure, slowly push downward on the clutch pedal until a slight resistance is felt.
      Fig 8: Measuring Clutch Pedal Free Play
      G03276097Courtesy of FORD MOTOR CO.
    • Is the clutch pedal free play less than 13 mm (0.5 in)? 
    1. Yes  : The clutch hydraulic system is OK. TEST the system for normal operation.
    2. No  : GO to C9.
  9. C9 CHECK CLUTCH PEDAL FREE PLAY WITH THE CLUTCH SLAVE CYLINDER DISCONNECTED 
    CAUTION: Do not bleed clutch hydraulic system.
    • With the vehicle in NEUTRAL, position on a hoist.
    • Clean the area around the connector. Using the special tool, disconnect the hydraulic line from the clutch slave cylinder.
      Fig 9: Disconnecting Hydraulic Line From Clutch Slave Cylinder
      G03276098Courtesy of FORD MOTOR CO.
    • Lower the vehicle.
    • Check the clutch pedal free play.
      Fig 10: Measuring Clutch Pedal Free Play
      G03276099Courtesy of FORD MOTOR CO.
    • Attach a tape measure to the cable tie.
    • While observing the tape measure, slowly push downward on the clutch pedal until a slight resistance is felt.
    • Is the clutch pedal free play less than 13 mm (0.5 in)? 
    1. Yes  : RECONNECT the hydraulic line to the clutch slave cylinder. GO to C10.
    2. No  : INSTALL a new clutch master cylinder. REFER to CLUTCH CONTROLS . DEPRESS and RELEASE the clutch pedal 15 full strokes. Clutch pedal should feel firm. RECHECK clutch pedal free play. If free play is greater than 13 mm (0.5 in), GO to C10.
  10. C10 BLEED THE CLUTCH SLAVE CYLINDER 
    • Remove the clutch reservoir cap and diaphragm. Check the fluid level. Fill the reservoir to or above the step mark. Install the cap and diaphragm.
    • Depress and release the clutch pedal several times to stabilize the clutch hydraulic system.
    • With the vehicle in NEUTRAL, position on a hoist.
    • Remove the bleeder screw cover and attach a vinyl hose to the bleeder hose. Place the other end of the vinyl hose into a clear container partially filled with brake fluid.
    • Have an assistant depress and release the clutch pedal five times, then hold the clutch pedal down. With the clutch pedal depressed, loosen the bleeder screw to let air escape the clutch system. Tighten the bleeder screw. Repeat this process until no air comes through the vinyl hose.
    • Tighten the bleeder screw and install the bleeder screw cover.
    • Slowly pump the clutch pedal several times to verify there is no fluid leakage.
      Fig 11: Bleeding Clutch Slave Cylinder
      G03276100Courtesy of FORD MOTOR CO.
    • Depress and release the clutch pedal two short cycles, and three full-travel cycles.
    • Make sure the clutch reservoir is at the correct level. Refill as necessary.
    • Does the clutch hydraulic system operate correctly? 
    1. Yes  : The clutch system is OK. TEST the system for normal operation.
    2. No  : VERIFY customer concern. CONDUCT a diagnosis of suspect components.
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