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'92-96 Hydraulic Clutch External Slave Cylinder Bleeding
1. Clean reservoir cap and cylinder clutch slave in area of the tube connection.
2. Remove cylinder clutch slave from the transmission bell housing.
3. Use a 3/32-inch diameter punch to drive out tube holding pin.
4. Remove the tube from the cylinder clutch slave and place tube end into a container for waste fluid.
NOTE: The tube is connected to the clutch master cylinder, so keep the clutch master cylinder reservoir cap tight to minimize fluid loss.
5. Hold cylinder clutch slave so connector port is at highest point, by tipping cylinder clutch slave to approximately 30 degrees. Fill with approved DOT 3 brake fluid through connector port.
NOTE: It may be necessary to "rock" cylinder clutch slave around or push gently on push rod to expel all the air. Pushing on push rod too hard will cause fluid to spray out of the connector hole.
NOTE: Do not allow any moisture or foreign matter to enter slave with brake fluid.
6. When all the air is expelled from the cylinder clutch slave and no more bubbles come out of the port hole, install cylinder clutch slave.
NOTE: Fluid is expelled from the connector port as the push rod is compressed, attaching it to the transmission and clutch release shaft.
7. Gravity fill the clutch master cylinder and tube as follows.
- Remove the clutch master cylinder reservoir cap and diaphragm.
- Fluid should flow out the open end of the tube into waste container. Be sure to keep the clutch master cylinder reservoir full.
- When fluid is flowing out in a steady, uninterrupted flow and fluid is level with step in clutch master cylinder reservoir, install cap and diaphragm.
- Install end of tube into cylinder clutch slave.
- Replace pin holding tube to body of cylinder clutch slave.
- Remove the slave cylinder from the transmission.
- Holding the cylinder so that the port for the tube is at the highest point, slowly push the pushrod into the cylinder and slowly let it return. Be sure the reservoir is full of fluid beforehand. Repeat this step two more times.
- Reattach the slave cylinder to the transmission.
- Rapidly depress the clutch pedal 10 times through a travel of approximately 1 inch. Wait two minutes.
- If the pedal is not hard within .25 inch to .5 inch of travel, repeat Step D.
8. System should be bled and functioning properly.
- To verify proper system function, set parking brake control (2780) and put vehicle in neutral.
- Start vehicle and shift into reverse gear.
- If gears grind, other components may be causing the concern.
- Check cylinder clutch slave push rod travel as described in this section.
Alternate Method
1. Gravity bleed system in place.
NOTE: If clutch release shaft cannot be moved toward front of vehicle, the clutch cable bracket is incorrectly set. Replace lever. Refer to «clutch master cylinder push rod» adjustment procedure in this section.
2. From under vehicle, with cylinder clutch slave bleed port closed, push external part of release lever slowly toward front of vehicle and release. Repeat this cycle 10-15 times until you no longer hear bubbles in the clutch master cylinder.
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