SMU - Bleeding Procedure for Hydraulic Clutch Release System Including Clutch Actuator Cylinder

The purpose of this bulletin is to inform technicians of the correct procedure for bleeding the Hydraulic Clutch Release System and/or Clutch Actuator Cylinder.

Notice: Discontinue Bench Bleeding of the Clutch Actuator Cylinder since seal damage could occur.

The eSI website will be updated immediately and future Service Stall SI CD releases will include this and other Service Manual updates.

Important: When using this procedure, DO NOT bench bleed any replaced parts prior to reassembling the Clutch Hydraulic System.

1. Verify that all the lines and fittings are dry and secure.
2. Tighten the bleed screw.

Tighten
Tighten the bleed screw to 7N·m(62 in-lbs).

3. Make sure clutch pedal is in the up position.
4. Clean dirt and grease from the reservoir cap in order to ensure that no foreign substances enter the system.
5. Remove reservoir cap.
6. Fill reservoir with hydraulic brake fluid, P/N 21013073 (in Canada, P/N 992668), to the maximum level.

Important: Brake fluid will deteriorate the rubber on J-45727. Use a clean shop cloth to wipe away the fluid after each use.

7. Install Rubber Stopper J-45727 to Vacuum Pump J-23738, or equivalent, with length of hose.
8. Place and hold stopper over top of reservoir to ensure a tight fit.
9. Operate pump to achieve 103-138kPa (15-20 psi) vacuum on gauge.
10. Hold vacuum for approximately one minute.
11. Slowly relieve vacuum and remove stopper from reservoir.
12. Replenish fluid to proper level.
13. Repeat steps 8 through 12 until all air is removed from the system.
14. Install reservoir cap.

Important: The clutch pedal will go to the floor on the first actuation, but will become firm as the Clutch Actuator Cylinder fills on following actuations.

15. Actuate the clutch 10-12 times to fill the Clutch Actuator Cylinder and also to ensure proper operation.

Caution: The vehicle could move if started in gear and the Clutch Actuator Cylinder was not properly filled in the previous step. Start the vehicle the first time in neutral to help prevent accidental vehicle movement.

16. Test drive vehicle to verify proper clutch operation and shifting.