Tools You'll Need:
* Clutch bleeding kit: This typically includes a clear hose, a container to catch the fluid, and possibly a one-way valve.
* Wrench: To loosen the bleed nipple on the clutch slave cylinder. The size will vary, so check your vehicle.
* Brake fluid: Use DOT 3 or DOT 4 brake fluid, never DOT 5 (silicone-based). Top up the master cylinder reservoir as needed.
* Rags or shop towels: To clean up spills.
* Helper: To pump the clutch pedal.
* Torque wrench (optional but recommended): To tighten the bleed nipple to the correct specification.
Procedure:
1. Locate the clutch slave cylinder bleed nipple: This is usually located on the slave cylinder itself, which is mounted on the transmission bellhousing. It might be difficult to access, requiring you to work under the van. Consult your repair manual for the exact location.
2. Locate the master cylinder reservoir: This is usually near the brake master cylinder. Top it up with fresh brake fluid to the maximum level indicated.
3. Attach the bleeding kit: Connect one end of the clear hose to the bleed nipple and the other end to a container to collect the old fluid.
4. Have your helper pump the clutch pedal: Instruct your helper to slowly and firmly pump the clutch pedal several times. *Do not let them fully depress the pedal* - this can cause air to be sucked into the system. They should pump it halfway.
5. Open the bleed nipple slightly: While your helper is pumping, carefully open the bleed nipple with your wrench. You should see brake fluid flowing through the hose; this may initially contain air bubbles.
6. Close the bleed nipple: Once the flow slows or stops, close the bleed nipple.
7. Repeat steps 4-6: Continue this process until the fluid running through the hose is clear and free of bubbles. You may need to top up the master cylinder reservoir several times during the bleeding process.
8. Check the fluid level: After completing the bleed, top up the master cylinder reservoir to the correct level.
9. Tighten the bleed nipple: Tighten the bleed nipple securely to the correct torque specification (consult your repair manual).
10. Test the clutch: Start the engine and test the clutch pedal. It should feel firm and engage smoothly. If it's still spongy or you have difficulty shifting, you may need to repeat the bleeding process or investigate a more serious problem (like a leak in the system or a faulty master/slave cylinder).
Important Considerations:
* Air in the system: Air in the clutch hydraulic system will result in a spongy clutch pedal or a clutch that doesn't disengage properly. Thorough bleeding is essential to remove all air.
* Brake fluid is corrosive: Wear gloves and eye protection to prevent skin and eye irritation. Clean up any spills immediately.
* Safety first: Work in a well-ventilated area and always use jack stands when working under your vehicle.
If you are uncomfortable performing this task yourself, it's best to take your van to a qualified mechanic. Improper bleeding can lead to clutch failure and potentially more costly repairs.
