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Pinpoint Test D: Clutch Drag

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. D1 CHECK FLUID LEVEL 
    • Key in OFF position.
    • Remove the reservoir cap and reservoir diaphragm.
    • Inspect the fluid level in the clutch master cylinder reservoir.
    • Is the fluid level at or above the step mark? 
    1. Yes  : INSTALL the reservoir cap and diaphragm. GO to D2.
    2. No  : ADD brake fluid. GO to D2 and CHECK for leaks. TEST the system for normal operation.
  2. D2 INSPECT THE CLUTCH HYDRAULIC SYSTEM FOR LEAKAGE 
    • Inspect the clutch master cylinder and the hydraulic lines for leakage.
    • Inspect the reservoir and reservoir line for leakage.
    • Inspect 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 D3.
  3. D3 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 D4.
  4. D4 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 1: Attaching Cable Tie To Lower Clutch Pedal
      G03276101Courtesy 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 2: Shifting Transmission Into First Gear
      G03276102Courtesy of FORD MOTOR CO.
    • While observing the tape measure, slowly engage the clutch, noting when the vehicle starts to move forward.
      Fig 3: Measuring Pedal Travel For Clutch Engagement
      G03276103Courtesy 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 D5.
  5. D5 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 4: Measuring Clutch Pedal Free Play
      G03276104Courtesy 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 D6.
  6. D6 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 5: Disconnecting Hydraulic Line From Clutch Slave Cylinder
      G03276105Courtesy of FORD MOTOR CO.
    • Lower the vehicle.
    • Check the clutch pedal free play.
      Fig 6: Measuring Clutch Pedal Free Play
      G03276106Courtesy 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 D7.
    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 D7.
  7. D7 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 7: Bleeding Clutch Slave Cylinder
      G03276107Courtesy 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.
    • Is the clutch pedal reserve greater than or equal to 25 mm (1 in) and 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 D8.
  8. D8 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 D9.
  9. D9 INSPECT THE CLUTCH DISC 
    • Carry out the clutch DISC CHECK .
    • Is the clutch disc OK? 
    1. Yes  : VERIFY the customer concern. GO to SYMPTOM CHART  if necessary.
    2. No  : INSTALL a new clutch disc. REFER to CLUTCH . TEST the system for normal operation.
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