Ford Falcon. Manual — part 258

308-02-5 Clutch

Controls 308-02-5

DIAGNOSIS AND TESTING (Continued)

Condition

Source

Action

CHECK Clutch Master Cylinder and

Clutch Master Cylinder

REFER to the Clutch Master Cylinder
Section.

Return clutch pedal spring damaged or

CHECK the clutch pedal and INSTALL

bad positioned

a new clutch pedal if necessary.

Worn or damaged clutch pedal

INSTALL a new clutch pedal.

Foreign object caught in clutch pedal

CHECK the clutch pedal.

Weak or broken clutch pedal return

CHECK the clutch pedal and INSTALL

Brake pedal does not return freely

spring

a new clutch pedal if necessary.

Foreign object caught in clutch pedal

CHECK the clutch pedal.

No response from the cruise control

CHECK the connection between the

Unconnected cruise switch

when the clutch pedal is pressed

cruise switch and the cruise control.

Faulty clutch pedal switch flag

INSTALL a new clutch pedal.

CHECK the cruise switch. REPLACE

Bad position of the cruise switch

or CHANGE cruise witch.

Nothing happening when the clutch

Connection between the low pressure

CHECK any leak, CHANGE low

pedal is pressed

line and master cylinder

pressure line if necessary.

Connection between the high pressure

CHECK any leak, CHANGE high

line and master cylinder

pressure line if necessary.

CHECK the fluid level and REFILL if

Fluid level

necessary.

CHECK the master cylinder, CHANGE

Master cylinder

it if necessary.

CHECK clutch pedal pad and

Discomfort on the clutch pedal

Clutch pedal pad worm or loose

CHANGE it if necessary.

Clutch Pedal Not Returning Once

Padal

feel

Go to PinPoint Test A

Released
"Raspy" Feel
Pedal Binding at Pivot
Pedal Pad Worn
Obstruction at / Under Pedal

Gears "CRUNCH" when changing

Clutch Master Cylinder Leaking /

Go to Section 308-01.

gears

Faulty

Gears hard to select

Clutch Slave Cylinder Leaking / Faulty

Go to Section 308-01.

Insufficient Master / Slave Cylinder

Go to PinPoint Test A

Rod Travel

Worn / Damaged Clutch Plate

Go to Section 308-01.

Damaged / Worn Clutch Pressure

Go to Section 308-01.

Plate

Manual Transmission Issue. Gears /

Go to Section 308-03.

Synchromesh Rings or Lack of
Lubrication

Refer to Clutch Diagnosis in Section

Air in System

308-01.

Cruise control not turning off when

Cruise Control Switch Faulty / Plug

Go to PinPoint Test A

clutch activated

Disconnected

Stop Lamp Switch Faulty / Plug

Go to PinPoint Test C in Section

Disconnected

206-06.

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308-02-6 Clutch

Controls 308-02-6

DIAGNOSIS AND TESTING (Continued)

Pinpoint Tests

PINPOINT TEST A : CRUISE CONTROL CLUTCH PEDAL CUT OFF SWITCH

Test Step

Result / Action to Take

A1

STOP LAMP CIRCUIT FUSE

Check the 15 Amp Fuse # 7 .

Yes

Replace Fuse and recheck.

Was Fuse blown?

NOTE: If Fuse blows again, this could indicate
an electrical system fault.

No

Go to A2

A2

CLUTCH PEDAL SWITCH CONTINUITY

Remove the clutch pedal switch. Refer to Section 308-01.

Yes

Go to A3

Carry out a continuity test. With the switch plunger Out = Continuity.

No

Push the switch plunger Inwards = Open circuit.

Replace the clutch pedal switch. Refer to

Push the switch pin Inwards = continuity.

Section 308-01.

Is the clutch pedal switch electrical function Okay?

A3

SWITCH EARTH CIRCUIT CONTINUITY

Disconnect the electrical connector C-111 at the clutch pedal switch

Yes

and the PCM connector.

PCM issue. Refer to Section 303-14.

Check the Blue/Yellow wire (92) from the switch connector C-111 to

No

the PCM terminal B05 RBS.

Check and repair wiring or terminal fault.

Was there continuity?

PINPOINT TEST B : PEDAL NOT RETURNING ONCE RELEASED

Test Step

Result / Action to Take

B1

HYDRAULIC SYSTEM

Check the fluid reservoir for clutch fluid.

Yes

Fill the reservoir with fluid. Refer to the

Was the reservoir empty?

specifications. Go to B2 to ensure that the
master cylinder is not leaking.

No

Go to B2

B2

HYDRAULIC HOSES

Carry out a visual inspection of the clutch hydraulic hoses and hose

Yes

clamps to see evidence of a leakage point.

Rectify cause of fluid leakage or replace the
offending hose.

Was a leak evident at the hoses, joints or clamps?

No

Go to B3

B3

MASTER CYLINDER

Carry out a visual inspection of the master cylinder push rod plunger

Yes

to cylinder area for signs of fluid leakage between push rod plunger

Replace the clutch master cylinder. Refer to

and the entry point to the master cylinder.

Section 308-02.

Was a leak evident?

No

Go to B4

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308-02-7 Clutch

Controls 308-02-7

DIAGNOSIS AND TESTING (Continued)

Test Step

Result / Action to Take

B4

RETURN SPRING

Carry out visual inspection of the Return spring at the pedal pivot for

Yes

damage.

Replace the complete Pedal box assembly.
Refer to Section 308-02.

Was the return spring damaged or broken?

No

Go to B5

B5

OBSTRUCTION

Check for an obstruction that could causing the pedal not to return

Yes

such as floor carpet, wiring harness jammed at the upper pivot area,

Rectify cause of obstruction.

etc.

No

Was an obstruction found?

There appears to be no issue with clutch pedal
return.

PINPOINT TEST C : CRUISE CONTROL CLUTCH PEDAL CUT OFF SWITCH

Test Step

Result / Action to Take

C1

PIVOT POINT BINDING OR "RASPY"

Remove the 2 x Torx head bolts used to retain the clutch master

Yes

cylinder to the pedal box.

Replace the clutch pedal / mount assembly.
Refer to Section 206-06.

Gently turn the flexible inlet hose to the master cylinder so that the it
is parallelWith the master cylinder body. This hose repositioning is

No

carried out to enable the hose to pass through the master cylinder to

Clutch pivot pin okay. Refit the clutch master

mounting opening.

cylinder.
Go to the clutch diagnosis section for slave

Gently withdraw the master cylinder (including flexible hose) through

cylinder and pressure plate diagnostics.

the opening. Allow to hang loose.

Manually push on the clutch pedal to evaluate if any binding at the
pivot pin or "raspy" effect is felt.

Did you notice any binding or "raspy" feel?

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308-02-8 Clutch

Controls 308-02-8

GENERAL PROCEDURES

Clutch Bleeding

1. Reconnect all lines and hoses and ensure routing

is correct. ie. Ensure there are no kinks or

siphons present in the soft lines (especially the

reservoir line). This is extremely important as the

system will be difficult or impossible to bleed if

siphons exist.

2. Fill the clutch reservoir to Full mark and keep

filled above 1/4 full at all times during bleed

procedure.

3. Pump the clutch pedal at a moderate pace

through its full travel ensuring the pedal returns

fully up against it’s stop. Note that the pedal may

need to be pulled back manually by hand to fully

return. Rapid pedal returns can be of assistance if

the clutch appears difficult to bleed.

4. Continue to pump the clutch pedal in bursts of 10

pumps with a rest for 5 seconds (with pedal fully

returned) in between.

5. After 30 seconds to a minute some pedal feel

should exist, continue the pumping/resting cycle

until the pedal has come up fully (up to approx 5

minutes). Some rapid pumping at the end of this

time may improve the bleed slightly but is not

necessarily required.

6. If there is some initial sponginess or play in the

first part of pedal travel at this stage continue with

a CSC bleed. This is normally only required if the

CSC has been drained or replaced. Elevate the

vehicle to gain access to the underside of the

transmission and bleed the CSC manually by

depressing the pedal fully and holding it down

whilst an assistant opens and then closes the

bleed port on the side of the clutch housing

(similar process to manually bleeding the brakes).

Repeat until pumped fluid is not aerated (usually

2-4 strokes). Note that approx 3 full strokes will

almost empty the reservoir. Ensure that fluid

remains in the reservoir at all times or the

procedure may need to be started again.

7. The Clutch system should now be fully bled.

Ensure that the reservoir is filled to Full mark and

test drive the vehicle to ensure that the clutch is

disengaging properly and not dragging. Note that

the system is self-bleeding and some slight

improvement will occur in pedal feel and take-up

point after the vehicle has sat for a few hours or

overnight after the above bleed procedure. This is

normal as any emulsified air will coalesce and

bleed out automatically during this time.

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