Clutch Hydraulic Circuit Bleeding

Courtesy of CHRYSLER GROUP, LLC

1. Verify fluid level in brake master cylinder, top off brake fluid as necessary.
2. Install a length of clear hose to divert fluid into suitable container.
3. Push and hold clutch pedal down, open bleeder (1) on slave cylinder, allow fluid to bleed out, then close bleeder. Repeat this step several times until no air is observed coming out of the bleeder. It may be necessary to return the clutch pedal by hand until the air is removed as there is not enough volume fluid displacement to return the clutch master cylinder by itself.
4. Remove drain hose and replace dust cap on bleeder and install slave cylinder on transmission.
5. Actuate clutch pedal 25 times, then start engine and verify clutch operation and pedal feel.
   NOTE:

   If clutch operation and pedal feel concerns are still present after this procedure, air is still trapped in the hydraulic circuit and you must be bleed with the Alternate Clutch Hydraulic System Bleeding Procedure.

ALTERNATE CLUTCH HYDRAULIC SYSTEM BLEEDING PROCEDURE 

1. Remove brake fluid reservoir cap.
   NOTE:

   Vacuum bleeding (through the bleeder screw) or pressure bleeding (through the reservoir) is recommended due to the powertrain angle that may trap air in the clutch slave cylinder. Follow equipment manufacturers directions when using either bleeding tool. 

2. Verify fluid level in brake master cylinder, top off brake fluid as necessary.

   Courtesy of CHRYSLER GROUP, LLC

3. Remove the bolt (1) that fastens the Clutch Slave Cylinder hydraulic line bracket to the transmission. Do not remove the hydraulic line or grommet from the bracket.
4. Remove the 2 nuts (2) which fasten the Clutch Slave cylinder (3) to the Transmission case.
   NOTE:

   Do not allow clutch slave cylinder plunger to pivot more than 2° in any direction in the clutch slave cylinder bore. Allowing the plunger to pivot more than 2° in the bore may cause fluid to bypass the seal and result in fluid leakage. 

5. Remove the Clutch Slave Cylinder (3) by pulling it straight back.
   NOTE:

   If removal of the clutch slave cylinder from the clutch hydraulic line has occurred (or any other depressurization of the clutch hydraulic system), it is best to prefill the clutch slave cylinder with brake fluid by hand prior to bleeding and reinstallation. 

6. Install a length of clear hose onto the bleeder screw to divert fluid into suitable container.
7. With the Clutch Slave Cylinder plunger pointed down and the hose end pointed up. Fully open the bleeder screw and fully depress the plunger by hand allowing any air bubbles to escape out of the bleeder screw.
8. Fully close the bleeder screw.
9. Release the Clutch Slave Cylinder plunger making sure that it extends to the end of its stroke.
   NOTE:

   Do not allow clutch slave cylinder plunger to pivot more than 2° in any direction in the slave cylinder bore. Allowing the plunger to pivot more than 2° in the bore may cause fluid to bypass the seal and result in fluid leakage. 

10. Repeat steps 7 - 9 at least five more times or until there are no more air bubbles observed through the clear hose.
11. Pull the clutch fork toward the clutch slave cylinder opening to ensure proper seating of the clutch slave cylinder plunger in the clutch fork pocket.
12. Install the clutch slave cylinder (3).

    Courtesy of CHRYSLER GROUP, LLC

    NOTE:

    Do not allow clutch slave cylinder plunger to pivot more than 2° in any direction in the clutch slave cylinder bore. Allowing the plunger to pivot more than 2° in the bore may cause fluid to bypass the seal and result in fluid leakage. 

13. Install the clutch slave cylinder hydraulic line bracket bolt (1) and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
14. Install the clutch slave cylinder nuts (2) and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
15. Actuate clutch pedal 50 times, making sure the pedal is getting to the top of its return stroke each time (this may require that you lift the pedal to the top of the stroke).
    NOTE:

    If the pedal fails to return after performing step 15 of this procedure, make certain that the push-rod end of the clutch slave cylinder is properly centered and sitting in the clutch fork pocket in the clutch/transmission housing. 

16. Engage the parking brake, verify the vehicle is in neutral, start engine, and verify clutch operation and pedal feel.
17. If the clutch pedal is not returning to the top of its stroke, or does not disengage the clutch, repeat the Alternate Clutch Hydraulic System Bleeding Procedure.