F 350 4WD Pickup V8-7.3L DSL Turbo VIN F (1994)
Clutch Master Cylinder: Service and Repair
Bleed Procedure
With Concentric Slave Cylinder
1. Using coupling disconnect tool No. T88T-70522-A or equivalent, disconnect hydraulic coupling at transmission by sliding white plastic sleeve
toward clutch slave cylinder while tugging on tube.
2. Clean area around clutch master cylinder reservoir cap, then remove cap and fill to step with suitable DOT 3 brake fluid.
3. Using screwdriver or equivalent tool, depress internal mechanism of male coupling to open valve. Then, while holding valve open, depress clutch
pedal fully and hold.
4. Remove screwdriver from coupling to close valve, then release clutch pedal. Clutch master cylinder must be kept full at all times to prevent air
from entering system.
5. Refill reservoir to step, then operate valve and clutch pedal as described above. Reservoir may again need to be filled.
6. Close reservoir, then reconnect coupling to clutch slave cylinder. When coupling is secured, cycle clutch pedal as quickly as possible through 5 to
10 strokes.
7. Wait 1 to 3 minutes, then repeat clutch pedal cycling 3 more times with 1 to 3 minutes between each set of 5 to 10 strokes.
8. Loosen clutch slave cylinder bleed screw, then depress and hold clutch pedal while torquing bleed screw to 2.2-3.7 ft lbs.
9. Refill reservoir to step, then check clutch operation. If clutch does not release fully, indicating air has remained in system, repeat procedure.
With External Slave Cylinder
1. Clean reservoir cap and slave cylinder in area of tube connection.
2. Remove slave cylinder from transmission bellhousing, then use a 3/32 inch punch to drive out pin that holds tube. Remove tube from slave
cylinder and place end into a container of waste fluid.
3. Hold slave cylinder so connector port is at an angle of approximately 30° then fill with approved DOT 3 brake fluid. Rock or push gently on push
rod to expel all air. Ensure no moisture or dirt enters slave cylinder.
4. Ensure all air is expelled, then install slave cylinder.
5. Gravity fill master cylinder and tube. Fluid should flow from open end of tube into waste container, but clutch master cylinder reservoir must be
kept full. When fluid is flowing at a steady rate and fluid level is at step in reservoir, install diaphragm and cap, then the end of tube into slave
cylinder.
6. Replace pin that holds tube to slave cylinder.
7. Remove slave cylinder from transmission. Then, while holding cylinder so that tube port is at highest point, push pushrod slowly into cylinder and
slowly release.
8. Install slave cylinder on transmission, then cycle clutch pedal rapidly 10 times through a travel of approximately 1 inch and wait 2 minutes. Pedal
should be hard within 1/4 to 1/2 inch of travel.
9. Verify correct clutch operation by starting vehicle and attempting to shift into Reverse from Neutral position. If gears clash, clutch hydraulic
system may not be fully bled, or other components may be at fault.
