Clutch Hydraulic System: Service and Repair

Clutch System Bleeding

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Special Tool(s)






Material(s)






General Procedure

1. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product MSDS (Material Safety Data Sheet), if available. Failure to follow these instructions may result in serious personal injury.

NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

NOTE: Do not reuse brake fluid.

With the vehicle in NEUTRAL, position it on a hoist. REFER to Lifting Points .

2. Remove the brake fluid reservoir cap.

3. Drain the brake fluid reservoir to the MIN mark.





4. Remove the clutch slave cylinder bleeder fitting dust cap.

5. Using 416-D002 , bleed the clutch system. Loosen the clutch slave cylinder bleeder fitting.

1. Fill the reservoir of 416-D002 with approximately 120 ml (4.06 fl. oz) of brake fluid.

2. Connect the reservoir hose to the clutch slave cylinder bleeder fitting.

3. Loosen the clutch slave cylinder bleeder fitting.

4. Pump approximately 100 ml (3.38 fl. oz) of brake fluid into the clutch system.






6. Tighten the clutch slave cylinder bleeder fitting,
- Tighten to 21 Nm (15 lb-ft).





7. Remove 416-D002.





8. Install the clutch slave cylinder bleeder fitting dust cap.

9. Check the fluid level in the brake fluid reservoir and add as necessary.





10. Install the brake fluid reservoir cap.

11. NOTE: Engage the reverse gear carefully.

Test the functionality of the clutch control system. Test the functionality of the clutch control system again after 30 seconds. If there are still abnormal noises, carry out Steps 2 through 11 again.

- Start the engine. After 2 seconds, press the clutch pedal and carefully engage the reverse gear. If there are abnormal noises, bleed the clutch control system automatically by pressing the clutch pedal 4 or 5 times. During bleeding, full travel of the clutch pedal must be reached.
- Test the functionality of the clutch control system again after 30 seconds. If there are still abnormal noises, carry out Steps 2 through 11 again.