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Pinpoint Test D

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.
  1. Remove the clutch master cylinder reservoir cap and reservoir diaphragm. Inspect the fluid level in the clutch master cylinder reservoir. Is the fluid level at or above the MAX mark? If so, install the clutch master cylinder reservoir cap and diaphragm and go to next step. If not, add High Performance DOT 3 Motor Vehicle Brake Fluid (C6AZ-19542-AB), check for leaks, test the system for normal operation and go to next step.
  2. 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? 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 go to next step. 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 0.51" (13 mm), bleed clutch slave cylinder. See BLEEDING  .
  7. Bleed clutch slave cylinder. See BLEEDING  . Is the clutch pedal reserve greater than or equal to 0.98" (25 mm) and 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.
  8. Remove the pressure plate. See CLUTCH ASSEMBLY  under REMOVAL & INSTALLATION. Inspect the pressure plate for wear or runout. Are there any signs of excessive wear or runout to the pressure plate? If so, install a NEW pressure plate. If not, go to next step.
  9. Inspect the clutch disc. Is the clutch disc okay? If so, verify the customer concern. If necessary, see SYMPTOM DIAGNOSIS (F150)  table under SYMPTOM DIAGNOSIS. If not, install a NEW clutch disc. Test the system for normal operation.
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