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Pinpoint Test C

WARNING: This page is about a different car, the 2002 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
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.
  1. Remove the clutch reservoir cap and clutch reservoir diaphragm. Check the fluid level of the clutch reservoir. Is the fluid level at or above the MAX mark? If so, install the clutch reservoir cap and diaphragm and go to next step. If not, add High Performance DOT 3 Motor Vehicle Brake Fluid (C6AZ-19542-AB), to the specified level and go to next step.
  2. 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? If so, install NEW components as necessary. Test the system for normal operation. If not, go to next step.
  3. 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 0.039" (1 mm). Does the fluid level increase more than 0.039" (1 mm)? If so, install a NEW master cylinder assembly. See CLUTCH MASTER CYLINDER & RESERVOIR  under REMOVAL & INSTALLATION. If not, go to next step.
    4. NOTE: The clutch reserve is the distance between the clutch pedal when fully depressed and the position when the vehicle starts to move forward.
  4. Park the vehicle on a level surface. Check for obstructions behind clutch pedal. Attach a cable tie to the lower clutch pedal. Attach a tape measure to the cable tie. Depress the clutch fully and start the vehicle. Shift the transmission into 1st gear. While observing the tape measure, slowly engage the clutch, noting when the vehicle starts to move forward. Is the clutch pedal reserve greater than or equal to 0.98" (25 mm)? If so, the clutch hydraulic system is okay. Test the system for normal operation. If not, go to next step.
    5. 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.
  5. Turn engine OFF and 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 0.51" (13 mm)? If so, the clutch hydraulic system is okay. Test the system for normal operation. If not, go to next step.
    6. CAUTION: DO NOT bleed clutch hydraulic system with the slave cylinder disconnected.
  6. With the vehicle in Neutral, position on a hoist. Raise and support the vehicle. Clean the area around the clutch slave cylinder connector. Using the Hydraulic Line Connector Remover (308-182, T88T-70522-A), disconnect the hydraulic line from the clutch slave cylinder. Lower the vehicle. Check the clutch pedal free play. See CLUTCH PEDAL FREE PLAY  under ADJUSTMENTS. Is the clutch pedal free play okay? If so, reconnect the hydraulic line to the clutch slave cylinder and bleed clutch slave cylinder. See BLEEDING  . If not, install a NEW clutch master cylinder. See CLUTCH MASTER CYLINDER & RESERVOIR  under REMOVAL & INSTALLATION. 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 0.5" (13 mm), bleed clutch slave cylinder. See BLEEDING  .
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