BLEEDING THE HYDRAULIC SYSTEM

Pickup and MPV

The clutch hydraulic system must be bled whenever the line has been disconnected or air has entered the system.

To bleed the system, remove the rubber cap from the bleeder valve and attach a rubber hose to the valve. Submerge the other end of the hose in a large jar of clean brake fluid. Open the bleeder valve. Depress the clutch pedal and allow it to return slowly. Continue this pumping action and watch the jar of brake fluid. When air bubbles stop appearing, close the bleeder valve and remove the tube.

During the bleeding process, the master cylinder must be kept at least ³⁄₄ full. After the bleeding operation is finished, install the cap on the bleeder valve and fill the master cylinder to the proper level. Always use fresh brake fluid, and above all, do not use the fluid that was in the jar for bleeding, since it contains air. Install the master cylinder reservoir cap.

Navajo

The following procedure is recommended for bleeding a hydraulic system installed on the vehicle. The largest portion of the filling is carried out by gravity. It is recommended that the original clutch tube with quick connect be replaced when servicing the hydraulic system because air can be trapped in the quick connect and prevent complete bleeding of the system. The replacement tube does not include a quick connect.

1. Clean the dirt and grease from the dust cap.
2. Remove the cap and diaphragm and fill the reservoir to the top with approved brake fluid C6AZ–19542–AA or BA, (ESA–M6C25–A) or equivalent.

   NOTE: To keep brake fluid from entering the clutch housing, route a suitable rubber tube of appropriate inside diameter from the bleed screw to a container.

3. Loosen the bleed screw, located in the slave cylinder body, next to the inlet connection. Fluid will now begin to move from the master cylinder down the tube to the slave cylinder.

   NOTE: The reservoir must be kept full at all time during the bleeding operation, to ensure no additional air enters the system.

4. Notice the bleed screw outlet. When the slave is full, a steady stream of fluid comes from the slave outlet. Tighten the bleed screw.
5. Depress the clutch pedal to the floor and hold for 1–2 seconds. Release the pedal as rapidly as possible. The pedal must be released completely. Pause for 1–2 seconds. Repeat 10 times.
6. Check the fluid level in the reservoir. The fluid should be level with the step when the diaphragm is removed.
7. Repeat Step 5 and 6 five times. Replace the reservoir diaphragm and cap.
8. Hold the pedal to the floor, crack open the bleed screw to allow any additional air to escape. Close the bleed screw, then release the pedal.
9. Check the fluid in the reservoir. The hydraulic system should now be fully bled and should release the clutch.
10. Check the vehicle by starting, pushing the clutch pedal to the floor and selecting reverse gear. There should be no grating of gears. If there is, and the hydraulic system still contains air, repeat the bleeding procedure from Step 5.