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Clutch System Bleeding

SPECIAL TOOL(S)

G04653267Courtesy of FORD MOTOR CO.
 Vacuum Pump Kit
416-D002 (D95L-7559-A)
MATERIAL

Item Specification
High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 or PM-1-C (US); CPM-1 or CPM-1-C (Canada) ESA-M6C25-A or WSS-M6C62-A
CAUTION: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled on a painted or plastic surface, wash the affected area immediately with cold water.
NOTE: Do not reuse brake fluid.
  1. Remove the brake fluid reservoir cap.
  2. Drain the brake fluid reservoir to the MIN mark.
    Fig 1: Locating Brake Fluid Reservoir To MIN Mark
    G04653268Courtesy of FORD MOTOR CO.
  3. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
  4. Remove the clutch slave cylinder bleed nipple dust cap.
  5. Using the special tool, bleed the clutch system.
    1. Fill the reservoir of the special tool with approximately 120 ml of brake fluid.
    2. Connect the reservoir hose to the clutch slave cylinder bleed nipple.
    3. Loosen the clutch slave cylinder bleed nipple.
    4. Pump approximately 100 ml of brake fluid into the clutch system.
      Fig 2: Identifying Special Tool To Bleed Clutch System
      G04653269Courtesy of FORD MOTOR CO.
  6. Tighten the clutch slave cylinder bleed nipple to 21 Nm (15 lb-ft).
    Fig 3: Tightening Clutch Slave Cylinder Bleed Nipple
    G04653270Courtesy of FORD MOTOR CO.
  7. Remove the special tool.
    Fig 4: Identifying Special Tool
    G04653271Courtesy of FORD MOTOR CO.
  8. Install the clutch slave cylinder bleed nipple dust cap.
  9. Install the brake fluid reservoir cap.
  10. Check the fluid level in the brake fluid reservoir and add as necessary.
    Fig 5: Locating Brake Fluid Reservoir
    G04653272Courtesy of FORD MOTOR CO.
    11. NOTE: Engage the reverse gear carefully.
  11. Test the functionality of the clutch control system.
    • Start the engine, after 2 seconds depress the clutch pedal, carefully engage the reverse gear. If there are abnormal noises, bleed the clutch control system automatically by depressing the clutch pedal 4 or 5 times. During bleeding, full travel of the clutch pedal must be reached.
    • Test the functionality of the clutch control system again after 30 seconds. If there are still abnormal noises carry out Steps  4 to  11 again.
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