Clutch Hydraulic System: Service and Repair

Hydraulic Clutch Bleeding

Tools Required

* J 35555 Metal MityVac
* J 43485 Power Steering Bleeder Adapter

Vacuum Bleeding

1. Verify that all the hydraulic lines are dry and secure.
2. Clean dirt and grease from the reservoir cap in order to ensure that no foreign substances enter the system.
3. Remove the reservoir cap.
4. Fill the reservoir using DOT 3 hydraulic fluid.

Important: Brake fluid will deteriorate the rubber on the J 44894-A, use a clean shop towel to wipe away all fluid after each use.

5. Install the J 43485 and the J 35555 to the reservoir.
6. Hold the J 43485 into position while applying 51-68 kPa (15-20 hg) of vacuum.
7. Remove the adapter and refill the reservoir
8. Fully depress the clutch pedal cycling the pedal for 30 seconds.
9. Lift the clutch pedal to the up stop position and hold for 30 seconds.
10. Repeat steps 4-9 until all air is removed from the clutch system.

Important: Do not start the engine while the transaxle is engaged, only while in the neutral position. This vehicle is equipped with a concentric slave cylinder (CSC) and will move if started in gear.

11. Place the vehicle into the neutral position and start the engine.
12. Pump the clutch pedal until firm.

Important: The clutch and braking systems are integrated into one reservoir. The brake may be soft when first applying.

13. Pump the brake pedal until firm.
14. If needed, add additional hydraulic fluid.
15. Road test the vehicle to ensure proper operation.

Manual Bleeding

Notice: Do not reuse the fluid that has been bled from a system in order to fill the clutch master cylinder reservoir for the following reasons:

1. The fluid may be aerated

2. The fluid may be contaminated

3. The fluid may contain too much moisture

Important: Maintain the fluid level in the clutch reservoir to the top step with DOT 3 hydraulic fluid.

1. Clean dirt and grease from the cap in order to ensure that no foreign substances enter the system.
2. Attach a hose to the bleeder port on the clutch actuator assembly. Submerge the other end of the hose in a container of DOT 3 hydraulic fluid.
3. Depress the clutch pedal quickly to the full depressed position.




4. Push the clip in order to move the clutch line into the bleed position.
5. Move the clutch line into the normal position ensuring that the clip returns.
6. Lift the clutch pedal to the up stop position and hold for 5 seconds.
7. Repeat steps 3-6 until air is purged from the clutch system.