Clutch System Bleeding

Special Tool(s)

Vacuum Pump Kit 416-D002 (D95L-7559-A) or equivalent

 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 Material Safety Data Sheet (MSDS) 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.

1. Make sure all hydraulic tubes are correctly seated.

2. Make sure the clutch pedal is in the most upward position.

3. Check the fluid level of the brake/clutch reservoir. Fill the reservoir with the specified fluid to the MAX mark.

4. Using a suitable bleeder kit and a Vacuum Pump Kit, install the rubber stopper in the reservoir opening. Make sure the rubber stopper has a tight fit.
   • Alternate method: use a 50 mm (1.96 in) rubber stopper with an 8 mm (0.31 in) pipe inserted through the rubber stopper.

5. Holding the rubber stopper in place, operate the vacuum pump to 15-20 inches of vacuum. Hold the vacuum for one minute, then quickly relieve the vacuum. Remove the special tools.

6. Check the fluid level of the reservoir. Fill the reservoir with the specified fluid to the MAX mark. Install the reservoir cap.

7. Depress and release the clutch pedal 10 to 12 times or until clutch pedal effort is consistent and positive at top of clutch pedal travel.

8. Repeat Steps 4 through 6 two additional times or until clutch pedal effort is consistent and positive at top of clutch pedal travel.

9. Install the reservoir cap.

10. Check the clutch pedal reserve. Test the clutch system for normal operation.