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I'm replacing the clutch and brake pedal assemply and I removed all 6 bolts but can't seem to get the shaft from the clutch and hose to come off.

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Should have some carter pins that need to come out?

Posted on Jul 04, 2010

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2004 ford focus 2.0liter. clutch pedaL GOES TO FLOOR. brake master full of fluid.I clutch master or clutch slave cylinder bad?


a plastic master cyl !

master cyl is bypassing internally

slave cylinder is inside the gearbox bell housing
if its leaking .....gearbox out




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Nov 11, 2016 | 2004 Ford Focus

Tip

2004 Hyundai Tiburon Clutch.


First you need to remove the Transaxle.

Manual Transaxle System REMOVAL

1. Remove the engine cover.
2. Remove the battery terminal.
3. Remove the air duct.
4. Remove the battery tray.
5. Remove the air cleaner.
(1) Upper
(2) Lower
6. Remove the back-up lamp switch.
7. After removing the CKP sensor, O2 sensor and oil pressure switch wiring bracket, separate the connectors.
8. Remove the brake fluid leveling sensor connector.
9. Remove the speedometer driven gear connector.
10. Remove the clutch release cylinder mounting bolt.
11. Remove the cotter pin of the shift cable (transaxle side).
12. Remove the cotter pin of the select cable. (transaxle side)
13. Remove the clip of the shift cable (transaxle side).
14. Remove the clip of the select cable (transaxle side).
15. Separate the steering column shaft joint.
16. Separate the power steering oil pump hose.
Be careful not to leak after separating.
17. Separate the hose after removing the clip of the power steering return hose.
18. Remove the upper connecting transaxle bolt.
19. Separate the start motor.
20. Install the engine support fixture.
21. After removing the tire, remove the caliper.
22. Remove the transaxle side cover.
23. Remove the transaxle side under cover.
24. Separate the tie rod end.
25. Remove the wheel speed sensor and the knuckle mounting bolt.
26. Drain the oil.
27. Remove the transaxle mounting bracket.
(1) Insulator bolt
(2) Body side mounting bolt (Upper)
(3) Body side mounting bolt (Side)
(4) Transaxle side mounting bolt.
28. Remove the front roll stopper.
(1) Insulator bolt
(2) Stopper bolt (Upper)
(3) Stopper bolt (Lower)
29. Remove the rear roll stopper.
(1) Insulator bolt
(2) Stopper bolt
30. Remove the drive shaft.
31. Remove the front muffler.
32. Remove the sub frame mounting bolt.
33. Install the transaxle jack.
34. Remove the transaxle lower mounting bolt to the engine.
35. Remove the transaxle assembly.

INSTALLATION
Installation is the reverse of the removal.

Then inspect and replace the clutch place and pressure plate.

INSTALLATION
1. Apply multipurpose grease to the release bearing contact surfaces and the release cylinder contact surface of the clutch release fork assembly.
When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. It can cause clutch slippage and judder.
2. Apply multipurpose grease into the groove of the release bearing.
3. Apply multipurpose grease to the clutch release lever fulcrum contact surface of the clutch release fork assembly.
4. Clean the surfaces of the flywheel and pressure plate thoroughly with fine sandpaper or crocus cloth, and make certain that all oil or grease has been removed.
5. Apply a small amount of multipurpose grease to the clutch disc splines and input shaft splines.
Do not apply more grease than necessary. Too much grease could cause clutch slip or judder.
6. Using the special tool, install the clutch disc to the flywheel. When installing the clutch disc, be sure that the surface having the manufactures stamp is towards the pressure plate side.
7. Install the the clutch cover assembly onto the flywheel and install the six (6) bolts through the clutch cover into the flywheel.
8. Tighten the bolts by one or two turns at a time, in succession, to avoid bending the cover flange.
If a special tool is not available, tighten the bolt temporarily and then torque to specification in diagonal torquing sequence indicated below.
TIGHTENING TORQUE
Single mass flywheel:
15~22 N·m (150~220 kg·cm, 11~16 lb·ft)
Dual mass flywheel:
20~27 N·m (200~270 kg·cm, 14~19 lb·ft)
9. Remove the special tool.
10. Install the transaxle. (Refer to GROUP - Manual Transaxle Assembly)
11. Adjust the clutch pedal free-play. (See CH-6)
INSPECTION
1. Check the diaphragm spring end for wear and uneven height.
Replace if wear is evident or height difference exceeds the limit.
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.
CLUTCH DISC
1. Check the clutch facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil, or grease, and replace the clutch disc if defective.
2. Measure the rivet sink and replace the clutch disc if it is out of specification
3. Check for torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.
If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.
CLUTCH RELEASE BEARING
The release bearing is packed with grease. Do not use cleaning solvent or oil.
1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.
INSTALLATION
Installation is the reverse of the removal.
Then remove pressure plate and Clutch plate.

1. Insert the special tool (that came with your clutch kit) in the clutch disc to prevent the disc from falling.
2. Loosen the bolts that attach the clutch cover to the flywheel in a star pattern.
3. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange.

on Jan 13, 2010 | Hyundai Tiburon Cars & Trucks

1 Answer

How to bleed clutch 2007 compass


GRAVITY BLEEDING CLUTCH HYDRAULIC CIRCUIT

1. Verify fluid level in brake master cylinder. Top off with DOT 3 brake fluid as necessary. Leave cap off.

2. Raise vehicle on hoist.

3. Remove bleed port protective cap and install suitable size and length of clear hose (4) to monitor and divert fluid into suitable container.

4. Open up the bleed circuit by turning the thumb screw (3) counter clockwise this will start the air purge and fluid fill process.

5. Lower vehicle, but only enough to gain access to and fill the brake master cylinder. NOTE: Do not allow clutch master cylinder to run dry while fluid exits bleed port.

6. Top off brake master cylinder fluid level while air is purged and fluid drains from bleed port. Continue this until no air bubbles are seen and a solid column of fluid exists.

7. Close hydraulic bleed circuit, remove drain hose and replace dust cap on bleed port.

8. From driver's seat, actuate clutch pedal 60-100 times.

9. Apply parking brake. Start engine and verify clutch operation and pedal feel. If pedal feels fine and clutch operates as designed, stop here. If pedal still feels spongy or clutch does not fully disengage, excessive air is still trapped within the system, most likely at the master cylinder.

10. Top off brake master cylinder fluid level with DOT 3 brake fluid as necessary.

POWER BLEEDING CLUTCH HYDRAULIC CIRCUIT

1. Remove reservoir cap and connect bleeder cap to reservoir. NOTE: Use Bleeder Cap/Modified reservoir cap adapter Snap-on #901-059 or equivalent.

2. Connect service filling machine to bleeder cap. NOTE: Use Service Filling Machine/Brake power bleeder Brake power bleeder or equivalent.

3. Service filling machine should be pressurized to at least 2.5 bar (36 PSI).

4. Remove dust cap from bleeder valve and connect the transparent bleeder hose to bleeder valve.

5. Place the other end of hose in the bleeder container to capture the used fluid. The end of the hose MUST be submerged in the DOT 3 brake fluid.

NOTE: Use Bleeder Container To capture hydraulic fluid and Transparent Bleeder Hose To route fluid to container.

6. Turn on the service filling machine.

7. Crack open the bleeder valve (3).

8. Allow fluid to flow out of bleed port until no more air bubbles can be seen in the transparent bleeder hose.

9. Once fluid is free of air bubbles; make 15 quick actuations between clutch pedal stop positions.

10. Close the bleeder valve and disconnect the service filling machine.

11. To remove remaining air, actuate pedal 10 times slowly between pedal stop positions.

12. Check clutch pedal to see if vehicle is properly bled.

13. If vehicle is not properly bled, repeat procedure.

14. Remove bleeder cap from reservoir and replace reservoir cap.

15. Disconnect transparent bleeder hose from bleeder valve and replace dust cap.

Oct 15, 2013 | 2007 Jeep Compass Limited

2 Answers

Where can I find the hydrolic clucth resivoir and why would it be empty. Daughters car she is in Illinois and me Florida. Not much help from here but can let her know where to look for sure?


There should be a small cup size reservoir on the fender strut tower. Looks like thing in upper right corner of below picture. What usually happens to hydraulic clutches when they draw air, it the slave cylinder on the side of the transmission leaks and must be replaced. The system can then be bled of air and proper clutch operation restored. It would be difficult to restore clutch operation just by refilling the reservoir, especially with such a small reservoir. If it is necessary to get the car moving to get it repaired (slave cylinder replacement is a big job on this car, as the transmission must be removed), one could bleed the system with the bad slave cylinder and then drive a short distance. The clutch will likely fail again after about 100 or so cycles of the pedal. I will paste the bleed instructions below. These require someone to get under the car to open the slave bleeder. If you have more questions, please let me know.

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Bleeding The Hydraulic System

Note: brake fluid is corrosive--please wipe any spilled fluid from painted or metal surfaces.
Manual Bleeding

  1. Fill the clutch reservoir with brake fluid. Check the reservoir level frequently and add fluid as needed.
  2. Connect one end of a vinyl tube to the bleeder plug on the slave cylinder and submerge the other end into a clear container half-filled with clean brake fluid.
  3. Slowly pump the clutch pedal 10-15 times without bring the pedal the full way up.
  4. Repeat Steps 2 and 3 until all of the air bubbles are removed from the system.
  5. Tighten the bleeder screw to 62 inch lbs. (7 Nm).
  6. Refill the master cylinder to the proper level.

Replacing the clutch slave cylinder:


Removal & Installation Before servicing any vehicle, please be sure to read the precautions section, which deals with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle.

  1. Disconnect the clutch master cylinder line from the transaxle by removing the C-clip.
  2. Remove the transaxle.
  3. Remove the clutch actuator cylinder bolts from the transaxle.
  4. Remove the clutch actuator cylinder.

To install:


NOTE Excessive amounts of lubricant on the input shaft splines can contaminate the clutch disc and cause clutch shudder.

  1. Lightly lubricate the inside diameter of the bearing with input shaft lubricant P/N 21005995 or equivalent.
  2. Install the clutch actuator cylinder (1) to the transaxle.
  3. Install the clutch actuator cylinder bolts.
  4. Tighten the bolts to 89 inch lbs. (10 Nm).
  5. Install the transaxle.
  6. Connect the clutch master cylinder line to the transaxle by pushing it in until it seats.
  7. Bleed the clutch hydraulic system.

Before servicing any vehicle, please be sure to read the precautions section, which deals with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle.
  1. Disconnect the clutch master cylinder line from the transaxle by removing the C-clip.
  2. Remove the transaxle.
  3. Remove the clutch actuator cylinder bolts from the transaxle.
  4. Remove the clutch actuator cylinder.

To install:


NOTE Excessive amounts of lubricant on the input shaft splines can contaminate the clutch disc and cause clutch shudder.

  1. Lightly lubricate the inside diameter of the bearing with input shaft lubricant P/N 21005995 or equivalent.
  2. Install the clutch actuator cylinder (1) to the transaxle.
  3. Install the clutch actuator cylinder bolts.
  4. Tighten the bolts to 89 inch lbs. (10 Nm).
  5. Install the transaxle.
  6. Connect the clutch master cylinder line to the transaxle by pushing it in until it seats.
  7. Bleed the clutch hydraulic system.

Oct 30, 2010 | 2003 Saturn VUE

1 Answer

How to remove the clutch peddle


Remove the clutch linkage from pedal (older models) then of the left side of the brake and clutch pedal remove the nut from the shaft and remove the pedal. Newer models with a clutch cable only require removing the nut because the cable is to the right of the brake pedal.

Oct 11, 2010 | Ford Escort Cars & Trucks

2 Answers

How to adjust clutch pedal on 86 mustang lx


clutch is supposed to be self adjusting. Here are instructions for replacing the adjuster:


REMOVAL & INSTALLATION


See Figure 1

  1. Disconnect the battery cable from the negative terminal of the battery.
  2. Remove the steering wheel using a steering wheel puller, Tool T67L-3600-A or equivalent.
  3. Remove the lower dash panel section to the left of the steering column.
  4. Remove the shrouds from the steering column.
  5. Disconnect the brake lamp switch and the master cylinder pushrod from the brake pedal.
  6. Rotate the clutch quadrant forward and unhook the clutch cable from the quadrant. Allow the quadrant to slowly swing rearward.
  7. Remove the bolt holding the brake pedal support bracket lateral brace to the left side of the vehicle.
  8. Disconnect all electrical connectors from the steering column.
  9. Remove the 4 nuts that hold the steering column to the brake pedal support bracket and lower the steering column to the floor.
  10. Remove the 4 booster nuts that hold the brake pedal support bracket to the dash panel.
  11. Remove the bolt that holds the brake pedal support bracket to the underside of the instrument panel, and remove the brake pedal support bracket assembly from the vehicle.
  12. Remove the clutch pedal shaft nut and the clutch pedal, as outlined above.
  13. Slide the self-adjusting mechanism out of the brake pedal support bracket.
  14. Examine the self-adjusting mechanism shaft bushings on either side of the brake pedal support bracket, and replace if worn.

To install:
  1. Lubricate the self-adjusting mechanism shaft with motor oil and install the mechanism into the brake pedal support bracket.
  2. Position the quadrant towards the top of the vehicle. Align the flats on the shaft with the flats in the clutch pedal assembly, and install the retaining nuts. Tighten to 32-50 ft. lbs. (43-67 Nm).
  3. Position the brake pedal support bracket assembly beneath the instrument panel, aligning the four holes with the studs in the dash panel. Install the four nuts loosely.
  4. Install the bolt through the support bracket and into the instrument panel. Tighten to 13-25 ft. lbs. (18-34 Nm).
  5. Tighten the four booster nuts that hold the brake pedal support bracket to the dash panel to 13-25 ft. lbs. (18-34 Nm).
  6. Connect the brake lamp switch and the master cylinder pushrod to the brake pedal.
  7. Attach the clutch cable to the quadrant.
  8. Position the steering column onto the four studs in the support bracket and start the four nuts.
  9. Connect the steering column electrical connectors.
  10. Install the steering column shrouds.
  11. Install the brake pedal support lateral brace.
  12. Tighten the steering column attaching nuts to 20-37 ft. lbs. (27-50 Nm).
  13. Install the lower dash panel section.
  14. Install the steering wheel.
  15. Connect the battery cable to the negative terminal on the battery.
  16. Check the steering column for proper operation.
  17. Depress the clutch pedal several times to adjust the cable.
  18. 714c4a4.gif

Sep 24, 2010 | Ford Mustang Cars & Trucks

3 Answers

Clutch pedal box has snapped off its mounting on vw polo


1-disconnect battery. 2- remove all lower dash plastic panels. 3- disconnect all plugs on steering coloumn. 4- remove shear bolts on steering coloumn, easy with a long 8" sharp chisel (get 2 x new shear bolts £0.50p each). 5-loosen & remove bolt at steering rack in drivers footwell, mark position of spline before removing this makes it east to refit (tipex). 6- pull steering coloumn out towards you & it will slide off the bush quite easy. 7- loosen clutch cable adjustment & remove cable nipple at pedal. 8-remove clutch pedal. 9- pull brake pedal out of plastic insert, this will break there is no way to remove this without breaking the plastic clip. get a new brake pedal clip insert for a Mk 3 golf £4 its the same (dont let VW sell you a new pedal) 10- remove 5 x nuts holding pedal box to bulkhead/brake servo. 11- cut 2 x cable ties holding throttle wiring & disconnetc plug above heater on drivers side. 12- push/pull brake servo slightly out of bulk head. 13- remove pedal box.
Cause of the problem- The clutch bracket is only held to the pedal box with 2 x spot welds & a 10mm tack on the top corner.
Repair- Fully Weld the clutch bracket to the pedal box. Great repair.
refitting reverse of above.
Duration around 6/8 hours Less if you get the spare parts before you start.
I wasted time trying to remove the brake pedal without breaking the clip impossible to do even with theVW tool. £4 on a new clip is well worth it.

Jan 30, 2010 | 2000 Volkswagen Golf

1 Answer

2001 audi a4 1.9tdi, hi i need to replace my clutch master cylinder for the rod has snapped, but i cant seem to figure out how to remove the clutch and brake pedal so as i can fit the new rod onto the...


YOU NEED A HAYNES MANUAL BECAUSE IT WILL SHOW AND TELL YOU HOW TO REMOVE CLUTCH MASTER CYLINDER.TO REMOVE CLUTCH MASTER CYLINDER YOU HAVE TO GO INSIDE THE VECHICLE AND REMOVE THE LEFT SIDE UNDER THE DASH PANEL.YOU HAVE TO UNCLIP AND SLIDE OUT PIN SECURING THE CLUTCH MASTER CYLINDER TO THE CLUTCH PEDAL.AND YOU WILL HAVE TO UNSCREW THE MOUNTING BOLTS AND DETACH THE MASTER CYLINDER FROM THE FIRE WALL.YOU WILL NEED HAYNES MANUAL.YOU HAVE TO REMOVE OTHER THINGS BEFORE DOING THE JOB.YOU NEED FLARE OR INLINE WRENCH ALSO.

Jan 29, 2010 | 2001 Audi A4

1 Answer

Info on do it tyour self clutch removal on 2001 mustang 3.8


REMOVAL:
  1. Lift clutch pedal to uppermost position to disengage clutch and brake pedal pivot shaft.
  2. Push clutch and brake pedal pivot shaft forward and unhook clutch release lever cable from clutch and brake pedal pivot shaft and allow it to slowly swing rearward.
  3. Raise and support vehicle.
  4. Remove clutch release lever dust shield.
  5. Disconnect clutch release lever cable from clutch release shaft.
  6. Remove retaining clip, then clutch release lever cable from flywheel housing.
  7. Remove starter motor from flywheel housing, then engine rear plate to front lower flywheel housing bolts.
  8. Remove transmission.
  9. Remove flywheel housing back just far enough to clear clutch pressure plate, then remove housing.
  10. Remove clutch release shaft from flywheel housing by pulling it through window in flywheel housing until retainer spring disengages from pivot.
  11. Remove clutch release hub and bearing from clutch release shaft.
  12. Loosen six clutch pressure plate bolts evenly to release spring tension gradually and avoid distorting clutch pressure plate. If same clutch pressure plate is to be installed, mark plate and flywheel so pressure plate can be installed in its original position.
  13. Remove clutch pressure plate and clutch disc from flywheel.
INSTALLATION:
  1. Position clutch disc and pressure plate assembly on flywheel, noting following:
    1. Three flywheel housing to block dowels on flywheel must be properly aligned with clutch pressure plate.
    2. Bent, damaged or missing flywheel housing to block dowels must be replaced.
    3. tart clutch pressure plate bolts but do not tighten.
    4. Avoid touching clutch disc face, dropping parts or contaminating parts with oil or grease.
    5. Align clutch disc using suitable alignment tool inserted in pilot bearing.
    6. To avoid clutch pressure plate distortion, alternately tighten bolts a few turns at a time, until they are all tight, then tighten to specifications.

  2. Install transmission to flywheel housing.
  3. Install engine rear plate to flywheel front lower housing bolts, then connect clutch release cable to flywheel housing and connect retaining clip.
  4. Connect clutch release lever cable to clutch release shaft, then install clutch release lever dust shield.
  5. Install starter motor.
  6. Lower vehicle, then install clutch release lever cable as follows:
    1. Lift clutch pedal to disengage clutch and brake pedal pivot shaft.
    2. Push clutch and brake pedal pivot shaft forward and hook end of clutch release lever cable over rear of clutch and brake pedal pivot shaft.

  7. Cycle clutch pedal several times to adjust clutch release lever cable

Aug 08, 2009 | 2001 Ford Mustang

1 Answer

Can a shade tree mechanic change the clutch in '97 mitsubishi 3000?


Removal (3000GT AWD)
1. Remove air cleaner cover, air hoses and vacuum pipe. Remove air cleaner, intake hose, battery, battery
tray and washer tank.
2. Disconnect transaxle control cables and speedometer cable. Raise and support vehicle.
3. Remove both inner fender splash shields. Remove clutch tube bracket and disconnect clutch release
cylinder (including clutch damper assembly on FWD models) and wire aside. Support transaxle assembly
with jack and disconnect upper transaxle mount. Remove mount, bracket, plug and stoppers.
4. Remove transaxle assembly upper coupling bolts. Disconnect tie rod ends and lower arm ball joints.
Remove right support member, starter cover (if equipped) and starter.
5. Remove left side bearing bracket mounting bolts and pry left axle shaft from transaxle. Wire left axle
shaft and inner shaft assembly aside. Pry right axle shaft from transaxle and wire aside.
6. Remove front bank side and rear bank side transaxle stays. Support transaxle assembly with a
transmission jack. Remove transaxle assembly lower coupling bolts and lower transaxle from vehicle.
7. Insert a clutch alining tool to prevent pressure plate and clutch disc from falling. Loosen pressure plate
bolts gradually in a crisscross pattern to avoid warping pressure plate flange. Remove pressure plate and
clutch disc.

May 14, 2008 | 1999 Mitsubishi 3000GT

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