B2BB0MK1 - 406D9 ML5T GEARBOX

OPERATION HYDRAULIC CLUTCH CONTROL

1 - IDENTIFICATION

LEFT HAND DRIVE

RIGHT HAND DRIVE

ALL MODELS

(1) Brake fluid reservoir .

(2) Hydraulic control master cylinder .

(3) Clutch pedal .

(4) Hydraulic control slave cylinder .

(5) Bleed screw .

2 - REMOVAL - REFITTING: HYDRAULIC CLUTCH CONTROL

Remove: The air cleaner and its outlet pipe .

Remove the filter from the brake fluid reservoir .

Drain the brake fluid reservoir using a clean syringe .

Drain the hydraulic circuit (With the bleed screw) .

2 - 1 - MASTER CYLINDER

Remove the trim under the fascia .

Remove the clevis pin (6) retained by a spring clip (7) .

Move aside ; The piston rod (8) .

Disconnect the pipe (9) .

Close the clutch cable hole .

Remove :

• the master-cylinder
• the brake servo unit

Move aside :

• the clip (10)
• the pipe (11)

Turn the clutch master cylinder a quarter turn clockwise .

Remove the clutch master cylinder .

2 - 2 - SLAVE CYLINDER

Move aside the clip (12) (Without removing) .

Move aside the pipe (13) .

Release the slave cylinder (14) from the hydraulic control (by pressing in the direction of the arrow (A) and slackening in the direction of the arrow (B), anti-clockwise) .

WARNING : do not use any tools to unfasten the cylinder - do not press the clutch pedal with the slave cylinder removed .

3 - REFITTING

Lightly grease the ball-joint (8) of the master cylinder (2) using ESSO NORVA 275 grease .

Lightly grease the slave cylinder piston rod end-piece on the clutch side with MOLYKOTE BR2 PLUS grease .

Proceed in the reverse order to removal .

Bleed the brakes .

Bleed the hydraulic clutch control .

4 - BLEEDING

IMPERATIVE : use only clean fluid free from bubbles; avoid any introduction of impurities into the hydraulic system .

Use only approved and recommended hydraulic fluid(s) : DOT4 .

IMPERATIVE : do not use automatic bleeding equipment (risk of foaming of the fluid in the circuit) .

Remove the air filter/connectors assembly (15) .

Fill the reservoir with brake fluid (1) to its maximum capacity .

NOTE : it is possible to operate the clutch pedal 7 times without it being necessary to add brake fluid to the reservoir .

Connect a transparent tube (16) to the bleed screw (5) and connect it to a receptacle (17) situated lower than the slave cylinder (4) .

Create a siphon (18) towards the top using the transparent pipe (16) which is in contact with the bottom of the receptacle .

Open the bleed screw .

Operate the clutch pedal (3) manually over its entire travel by 7 rapid forwards and backwards movements (1 forward and backward movement per second) .

Leave the clutch pedal (3) at the end of its travel on the last movement .

Close the bleed screw (5) .

Raise the clutch pedal (3) to its highest position .

Again : Fill the reservoir with brake fluid (1) to its maximum capacity .

Open the bleed screw (5) .

Operate the clutch pedal (3) manually over its entire travel by 7 rapid forwards and backwards movements (1 forward and backward movement per second) .

Leave the clutch pedal (3) at the end of its travel on the last movement .

Close the bleed screw (5) .

Raise the clutch pedal (3) to its highest position .

If necessary ; Repeat the operation .

Top up the brake fluid level to the MAXI mark on the reservoir .

Release and engage the clutch rapidly 40 times (1 forward and backward movement per second) .

Start the engine .

Apply the handbrake .

Engage a gear .

Check that a start of friction of the clutch mechanism occurs at a distance X greater than or equal to 35 mm (Distance (X) is given as an indicator) .

If incorrect : Repeat the bleed operations .

Bolt(s) (5) to 0.75 m.daN .