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Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 944 (Manual Transaxle/Transmission And Clutch - General Information) >> Diagnostic Tests >> Manual Transmission and Clutch >> Pinpoint Tests >> Pinpoint Test C: Clutch Hydraulic System Check

Pinpoint Test C: Clutch Hydraulic System Check

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. C1 CHECK THE FLUID LEVEL 
      Fig 1: Locating Clutch Reservoir Cap
      GF0010413Courtesy of FORD MOTOR CO.
      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.
    • 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.
      • Fig 2: Attaching Cable Tie And Tape Measure To Pedal
      GF0003821Courtesy of FORD MOTOR CO.
    • 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.
      • Fig 3: Identifying Gear Shifting Lever
      GF0003825Courtesy of FORD MOTOR CO.
    • Shift the transmission into 1st gear.
      • Fig 4: Releasing Clutch And Measuring Engagement Point
      GF0010414Courtesy of FORD MOTOR CO.
    • 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 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.
      • Fig 5: Locating Inspection Plug
      GF0010415Courtesy of FORD MOTOR CO.
    • Remove the inspection plug.
      • Fig 6: Locating Index-Mark On Rear Of Bearing
      GF0010416Courtesy of FORD MOTOR CO.
      Fig 7: Measuring Distance Between Index Marks
      GF0010417Courtesy 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 2 index marks.
    • 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 Clutch 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 
    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.
      • Fig 8: Checking Clutch Pedal Free Play With Clutch Slave Cylinder Disconnected
      GF0003822Courtesy of FORD MOTOR CO.
    • 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  : 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.
      • Fig 9: Using Special Tool To Disconnect Hydraulic Line From Clutch Slave Cylinder
      GF0003823Courtesy of FORD MOTOR CO.
    • Clean the area around the connector. Using the special tool, disconnect the hydraulic line from the clutch slave cylinder.
    • Lower the vehicle.
      • Fig 10: Checking Clutch Pedal Free Play With Clutch Slave Cylinder Disconnected
      GF0003822Courtesy of FORD MOTOR CO.
    • Check the clutch pedal free play.
    • 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 5 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.
      • Fig 11: Bleeding Clutch Slave Cylinder
      GF0003824Courtesy of FORD MOTOR CO.
    • Slowly pump the clutch pedal several times to verify there is no fluid leakage.
    • Depress and release the clutch pedal 2 short cycles, and 3 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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