Clutch feels spongy??
Champion
Joined: Oct 2004
Posts: 4,114
Likes: 0
From: RI
RE: Clutch feels spongy??
Heres a post from another forum on what people who have had problems with their clutches have done. This is from the FACTORY SERVICE MANUAL! For the 2.4l i4 Turbocharged engine only.
Clutch Bleed procedure/Clutch pedal adjustment
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Some People have had problems with their trasmissions/clutches. This is the FSM Bleeding procedure for the T850 transmission clutch hydraulic system. It has been posted before but I am putting this up so everyone can see it if and when they get a similar problem. I just recently replaced Jeans Slave cylinder and soon the master cylinder. I have done the bleeding procedure as described and does work nicely. *DCX says it's a non bleed system*
Procedure for bleeding Clutch Hydraulics
2.4L Engine (With Turbo)
From driver’s seat, actuate clutch pedal 60–100 times. Verify clutch operation/pedal feel. If pedal still feels spongy, or clutch does not fully disengage, excessive air is still trapped within the system. Perform the following procedure:
(1) Verify fluid level in clutch master cylinder reservoir.
Top off with DOT 3 brake fluid as necessary.
(2) Raise vehicle on hoist.
(3) Remove clutch slave cylinder/damper assembly from the transaxle case, but do not disconnect from the hydraulic system. Lift nylon tab
with a small screwdriver, and then depress cylinderinward towards case and rotating cylinder 60° counter-clockwise. Allow the slave cylinder hang, making it the lowest part of the system.
CAUTION: While slave cylinder is detached from the
transaxle, DO NOT actuate the clutch master cylinder.
Damage to the slave cylinder will result.
(4) Depress slave cylinder pushrod until it bottoms and then release. Repeat this at least ten (10) times, forcing trapped air upwards and out of the system.
(5) Install clutch slave cylinder into position, noting orientation of different sized lugs. While depressing inward, rotate slave cylinder clockwise until nylon locating tab rests in transaxle case cutout, and the hydraulic tube is vertical
(6) Lower vehicle.
(7) Check and adjust clutch master cylinderfluid level. Actuate clutch pedal thirty (30) times. Verify clutch operation/pedal feel. If pedal still feels spongy,
or clutch does not fully disengage, air is still trapped within the system. Repeat Step 3 - Step 7 until air is purged. If several attempts at purging air from the system are unsuccessful, replace both the clutch master cylinder and slave cylinder assemblies.
(8) Raise vehicle.
(9) Lower vehicle.
(10) Top off clutch master cylinderfluid level with
DOT 3 brake fluid as necessary.
SPECIFICATIONS CLUTCH/HYDRAULICS/PEDALS TORQUE SPECIFICATIONS
~ DESCRIPTION /N·m /Ft. Lbs. / In. Lbs. ~
Brake/Clutch Pedal & Booster-to-Dash Nuts: ......... 34 — 300
Brake/Clutch Pedal Assembly-to-Instrument Panel: 34 — 300
Clutch Cover-to-Flywheel Bolts: ........................... 29 — 250
Clutch Pedal Pivot Shaft Nut: ................................ 42 31 —
Damper-to-Transaxle Nuts: .................................. 24 — 215
Driveplate-to-Crankshaft Bolts: ............................ 95 70 —
Flywheel-to-Crankshaft Bolts: .............................. 95 70 —
Master Cylinder Pushrod Adj. Screw: ..................... 6 — 55
Modular Clutch-to-Drive Plate Bolts: ..................... 88 65 —
Master Cylinder Mounting Nuts (LHD): ................... 15 — 130
Master Cylinder Reservoir Mounting bolts (LHD): .... 11 — 100
Transaxle-to-Engine Mounting Bolts: ..................... 95 70 —
Clutch pedal Adjustment
Loosen the 8mm adjustment screw, Gently lift up clutch pedal until the clutch pedal fully depresses the Upstop switch.
Torque Adjustment screw to 6 N.m (55 in. Lbs.)
Here is a good thread about the clutch pedal adjustment with a pic!
Clutch Bleed procedure/Clutch pedal adjustment
--------------------------------------------------------------------------------
Some People have had problems with their trasmissions/clutches. This is the FSM Bleeding procedure for the T850 transmission clutch hydraulic system. It has been posted before but I am putting this up so everyone can see it if and when they get a similar problem. I just recently replaced Jeans Slave cylinder and soon the master cylinder. I have done the bleeding procedure as described and does work nicely. *DCX says it's a non bleed system*
Procedure for bleeding Clutch Hydraulics
2.4L Engine (With Turbo)
From driver’s seat, actuate clutch pedal 60–100 times. Verify clutch operation/pedal feel. If pedal still feels spongy, or clutch does not fully disengage, excessive air is still trapped within the system. Perform the following procedure:
(1) Verify fluid level in clutch master cylinder reservoir.
Top off with DOT 3 brake fluid as necessary.
(2) Raise vehicle on hoist.
(3) Remove clutch slave cylinder/damper assembly from the transaxle case, but do not disconnect from the hydraulic system. Lift nylon tab
with a small screwdriver, and then depress cylinderinward towards case and rotating cylinder 60° counter-clockwise. Allow the slave cylinder hang, making it the lowest part of the system.
CAUTION: While slave cylinder is detached from the
transaxle, DO NOT actuate the clutch master cylinder.
Damage to the slave cylinder will result.
(4) Depress slave cylinder pushrod until it bottoms and then release. Repeat this at least ten (10) times, forcing trapped air upwards and out of the system.
(5) Install clutch slave cylinder into position, noting orientation of different sized lugs. While depressing inward, rotate slave cylinder clockwise until nylon locating tab rests in transaxle case cutout, and the hydraulic tube is vertical
(6) Lower vehicle.
(7) Check and adjust clutch master cylinderfluid level. Actuate clutch pedal thirty (30) times. Verify clutch operation/pedal feel. If pedal still feels spongy,
or clutch does not fully disengage, air is still trapped within the system. Repeat Step 3 - Step 7 until air is purged. If several attempts at purging air from the system are unsuccessful, replace both the clutch master cylinder and slave cylinder assemblies.
(8) Raise vehicle.
(9) Lower vehicle.
(10) Top off clutch master cylinderfluid level with
DOT 3 brake fluid as necessary.
SPECIFICATIONS CLUTCH/HYDRAULICS/PEDALS TORQUE SPECIFICATIONS
~ DESCRIPTION /N·m /Ft. Lbs. / In. Lbs. ~
Brake/Clutch Pedal & Booster-to-Dash Nuts: ......... 34 — 300
Brake/Clutch Pedal Assembly-to-Instrument Panel: 34 — 300
Clutch Cover-to-Flywheel Bolts: ........................... 29 — 250
Clutch Pedal Pivot Shaft Nut: ................................ 42 31 —
Damper-to-Transaxle Nuts: .................................. 24 — 215
Driveplate-to-Crankshaft Bolts: ............................ 95 70 —
Flywheel-to-Crankshaft Bolts: .............................. 95 70 —
Master Cylinder Pushrod Adj. Screw: ..................... 6 — 55
Modular Clutch-to-Drive Plate Bolts: ..................... 88 65 —
Master Cylinder Mounting Nuts (LHD): ................... 15 — 130
Master Cylinder Reservoir Mounting bolts (LHD): .... 11 — 100
Transaxle-to-Engine Mounting Bolts: ..................... 95 70 —
Clutch pedal Adjustment
Loosen the 8mm adjustment screw, Gently lift up clutch pedal until the clutch pedal fully depresses the Upstop switch.
Torque Adjustment screw to 6 N.m (55 in. Lbs.)
Here is a good thread about the clutch pedal adjustment with a pic!
