Clutch: Service and Repair
STANDARD PROCEDURE - BLEEDING CLUTCH HYDRAULIC CIRCUITNOTE: It is necessary to bleed the clutch hydraulic release system if the system has lost an excessive amount of fluid and has ingressed air into the circuit. Air in the system typically results in a spongy pedal feel, and/or improper clutch release. If air cannot be removed from the system using this procedure, it is necessary to replace BOTH the clutch master cylinder and slave cylinder assemblies.
2.0 Engines (Except Turbo)
From driver's seat, actuate clutch pedal 60-100 times. Verify clutch operation/pedal feel. If pedal still feels spongy, or clutch does not fully disengage, excessive air is still trapped within the system. Perform the following procedure:
1. Verify fluid level in clutch master cylinder reservoir. Top off with DOT 3 brake fluid as necessary.
2. Raise vehicle on hoist.
3. Remove clutch slave cylinder assembly from the transaxle case (Fig. 4), but do not disconnect from the system. Allow the slave cylinder hang, making it the lowest part of the system.
CAUTION: While slave cylinder is detached from the transaxle, DO NOT actuate the clutch master cylinder. Damage to the slave cylinder will result.
4. Depress slave cylinder pushrod until it bottoms and then release. Repeat this at least ten (10) times, forcing trapped air upwards and out of the system.
5. Re-install slave cylinder into position. Torque slave cylinder to case bolt to 19 Nm (168 inch lbs.).
6. Lower vehicle.
7. Check and adjust clutch master cylinder fluid level. Actuate clutch pedal thirty (30) times. Verify clutch operation/pedal feel. If pedal still feels spongy, or clutch does not fully disengage, air is still trapped within the system. Repeat Step 3 - Step 7 until air is purged. If several attempts at purging air from the system are unsuccessful, replace both the clutch master cylinder and slave cylinder assemblies.
8. Raise vehicle.
9. Lower vehicle.
10. Top off clutch master cylinder fluid level with DOT 3 brake fluid as necessary.
24.L Engine (With Turbo)
From driver's seat, actuate clutch pedal 60-100 times. Verify clutch operation/pedal feel. If pedal still feels spongy, or clutch does not fully disengage, excessive air is still trapped within the system. Perform the following procedure:
1. Verify fluid level in clutch master cylinder reservoir. Top off with DOT 3 brake fluid as necessary.
2. Raise vehicle on hoist.
3. Remove clutch slave cylinder/damper assembly from the transaxle case (Fig. 5), but do not disconnect from the hydraulic system. Lift nylon tab with a small screwdriver, and then depress cylinder inward towards case and rotating cylinder 60° counter-clockwise. Allow the slave cylinder hang, making it the lowest part of the system.
CAUTION: While slave cylinder is detached from the transaxle, DO NOT actuate the clutch master cylinder. Damage to the slave cylinder will result.
4. Depress slave cylinder pushrod until it bottoms and then release. Repeat this at least ten (10) times, forcing trapped air upwards and out of the system.
5. Install clutch slave cylinder into position, noting orientation of different sized lugs. While depressing inward, rotate slave cylinder clockwise until nylon locating tab rests in transaxle case cutout, and the hydraulic tube is vertical (Fig. 5).
6. Lower vehicle.
7. Check and adjust clutch master cylinder fluid level. Actuate clutch pedal thirty (30) times. Verify clutch operation/pedal feel. If pedal still feels spongy, or clutch does not fully disengage, air is still trapped within the system. Repeat Step 3 - Step 7 until air is purged. If several attempts at purging air from the system are unsuccessful, replace both the clutch master cylinder and slave cylinder assemblies.
8. Raise vehicle.
9. Lower vehicle.
10. Top off clutch master cylinder fluid level with DOT 3 brake fluid as necessary.