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Home >> Mercury >> 2008 >> Milan Base, 2.3 Z, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 1193 (Manual Transmission & Clutch - General Information) >> Diagnostic Tests >> Manual Transmission and Clutch >> Pinpoint Tests >> Pinpoint Test C: Clutch Pedal Feels Spongy or Has Excessive Travel. Clutch Will Not Disengage >> Pinpoint Test C: Clutch Pedal Feels Spongy Or Has Excessive Travel. Clutch Will Not Disengage

Pinpoint Test C: Clutch Pedal Feels Spongy Or Has Excessive Travel. Clutch Will Not Disengage

WARNING: This page is about a different car, the 2009 Ford Mustang. 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 brake and clutch reservoir cap.
    • Check the fluid level of the brake and clutch reservoir.
    • Is the fluid level at or above the step mark? 
    1. YES  : INSTALL the reservoir cap. 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.
    • 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: Identifying Cable Tie To Clutch Pedal
      GF0015713Courtesy 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: Shifting Transmission Into 1st Gear
      GF0015714Courtesy of FORD MOTOR CO.
    • Shift the transmission into 1st gear.
      • Fig 4: Identifying Steering Wheel Reference Point
      GF0015715Courtesy of FORD MOTOR CO.
    • Use the seam on the steering wheel as a reference point.
      • Fig 5: Engaging Clutch While Observing Tape Measure
      GF0015716Courtesy 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 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  C6.
  6. C6 INSPECT THE CLUTCH DISC 
    NOTE: Vehicles equipped with a 4.0L engine use an inner floating damper design disc. When inspecting the disc, a rattle type noise can be heard. This is a normal condition.
    1. YES  : Go to  C7.
    2. NO  : INSTALL a new clutch disc. REFER to CLUTCH . TEST the system for normal operation.
  7. C7 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 6: Checking Clutch Pedal Free Play
      GF0015717Courtesy 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  : BLEED the clutch hydraulic system. REFER to Clutch System Bleeding . TEST the system for normal operation.
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