The Procedure:
Under normal conditions, disconnecting the clutch coupling will not introduce air into the system. However, if there appears to be air in the system (spongy pedal, or insufficient bearing travel), the system must be bled. The following procedure is used with the hydraulic system installed on the vehicle.
1. Disconnect the coupling at the transmission with Clutch Coupling Tool T88T-70522-A by sliding the white plastic sleeve toward the slave cylinder while applying a slight tug on the clutch tube.
2. Clean dirt and grease from around the reservoir cap.
3. Remove cap and diaphragm and fill reservoir to the step with Heavy Duty Brake Fluid C6AZ-19542-AA or -BA (ESA-M6C25-A) or equivalent. Brake fluid must be certified to DOT 3 specification.
4. Using a small screwdriver, depress the internal mechanism of the male coupling to open the valve. While continuing to hold the valve open, slowly depress the clutch pedal to the floor and hold.
5. Remove the screwdriver from the coupling, closing the valve.
6. Release the clutch pedal.
7. Refill reservoir to level at step.
NOTE:
The reservoir must be kept full at all times to ensure that there will be no additional introduction of air to the system.
8. Repeat Steps 4 through 7.
9. Close reservoir. Reconnect the coupling to the slave cylinder. Check that the connection is secure by applying a slight tug to the clutch tube.
10. Stroke the clutch pedal as rapidly as possible for 5 to 10 strokes.
11. Wait 1 to 3 minutes.
12. Repeat Steps 10 and 11 three more times.
13. Loosen bleed screw (located in the slave cylinder body next to the inlet connection).
14. Depress and hold clutch pedal while tightening bleed screw to 3-5 N-m (2.2-3.7 ft-lb).
15. Refill reservoir to level at step.
16. The hydraulic system should now be fully bled and should properly release the clutch. Check clutch reserve as described in this section.
