Bleed Procedure, External Clutch Slave Cylinder, 7.3L Diesel and 7.5L Gasoline Engines

1. NOTE: When bleeding a dry replacement clutch master cylinder (7A543), remove tube from vehicle and connect to clutch master cylinder. Perform bench bleed procedure. Refer to Section 08-02.

   Clean reservoir cap and clutch slave cylinder in area of the tube connection.

2. Remove clutch slave cylinder from the transmission bell housing.

3. Use a 3/32-inch diameter punch to drive out tube holding pin.

4. NOTE: The tube is connected to the clutch master cylinder, so keep the clutch master cylinder reservoir cap tight to minimize fluid loss.

   Remove the tube from the clutch slave cylinder and place tube end into a container for waste fluid.

5. NOTE: It may be necessary to rock clutch slave cylinder 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.

   Hold clutch slave cylinder so connector port is at highest point, by tipping clutch slave cylinder to approximately 30 degrees. Fill with Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A through connector port.

6. NOTE: Fluid is expelled from the connector port as the push rod is compressed, attaching it to the transmission (7003) and clutch release lever.

   When all the air is expelled from the clutch slave cylinder and no more bubbles come out of the port hole, install clutch slave cylinder.

   
   
   
   
   

7. Gravity fill the clutch master cylinder and tube as follows.

   1. Remove the clutch master cylinder reservoir cap and diaphragm.
   2. Fluid should flow out the open end of the tube into waste container. Be sure to keep the clutch master cylinder reservoir full.
   3. 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.
   4. Install end of tube into clutch slave cylinder.
   5. Replace pin holding tube to body of clutch slave cylinder.
   6. Remove the slave cylinder from the transmission.
   7. Holding the cylinder so that the port for the tube is at the highest point, slowly push the push rod into the cylinder and slowly let it return. Be sure the reservoir is full of fluid beforehand. Repeat this step two more times.
   8. Reattach the slave cylinder to the transmission.
   9. Rapidly press the clutch pedal 10 times through a travel of approximately 1 inch. Wait two minutes.
   10. If the pedal is not hard (within 6.35-12.7mm [0.25-0.5 inch] of travel), repeat Steps d through i.

8. System should be bled and functioning properly. To verify proper system function, perform the following:

   1. Set parking brake control (2780) and put vehicle in neutral.
   2. Start vehicle and shift into reverse gear.
   3. If gears grind, other components may be causing the concern.
   4. Check clutch slave cylinder push rod travel. Refer to Clutch Master Cylinder Push Rod Adjustment in the Adjustments portion of this section.

Alternate Method

1. Gravity bleed system in place.

2. NOTE: If clutch release lever (7515) cannot be moved toward front of vehicle, the clutch master cylinder lever is incorrectly set. Replace lever. Refer to Clutch Master Cylinder Push Rod Adjustment in the Adjustments portion of this section.

   From under vehicle, with clutch slave cylinder bleed port closed, push external part of clutch 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.