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While all Mk I Mondeos (except for maybe some of the very latest ones prior to the Mk II release) have a mechanical clutch assembly, Mk II and onwards are hydraulic. If you've at any point disconnected the clutch hydraulics, this needs bleeding, in order to get the air out of the system.
- A one-man brake/clutch bleeding kit, like Mityvac, Vacula, or Gunson Ezibleed.
These instructions are based on experience with Ezibleed, which is commonly sold at Halfords.
- A slightly overpressured spare tyre. (20psi max)
Preparation (Gunson kit)
The Ezibleed kit consists of:
- a bottle
- a special cap with two hoses coming out of it
a bag with
- four holed screw caps
- three hoses
Discard the two small screw caps for now, and concentrate on the two big ones. The narrowest of the two (44 mm) will fit the Mondeo, and possibly other Ford models as well. Once you've confirmed the cap fits your brake fluid reservoir, fit it to the smaller of the two hoses coming out of the bottle's cap (the clear one):
- Undoing the first nut at the loose end of the clear hose
- Remove the first of the two washers, and make sure the second one stays on the threaded piece of metal tubing
- Put the cap that fits onto the threads, with the hose coming out the outside of it
- Put the first washer back on to the tubing, which is now inside the cap
- Put the nut back on to the tubing, and tighten up on both sides of the cap
Two of the three loose hoses will fit the clutch bleed valve, although one will fit more loosely than the other. Make sure that you pick the tightest fit of the two.
Testing the kit
Test the kit if you haven't done that already, as you want to know that it can handle the pressure:
- Set tyre pressure to around 20psi.
- Make sure the bottle is tight, and connect the black hose to the tyre valve.
- Pinch the clear hose tight, and open the flip valve.
- Wait a few minutes. If the container stays tight, it should handle the pressure.
- Bring the spare tyre out, and put it down next to the left front wheel, valve facing up and towards the fitted wheel
- Pop the hood, and locate the following components:
- Brake fluid reservoir
- Clutch bleeder valve
- Connect the black hose to the spare tyre, and make sure you shut the flip valve at the end of that hose properly
- Fill the bottle in the kit with clean brake fluid, DOT4, and screw its cap on
- Undo the cap on the clutch bleeder valve, and connect the drain hose to it
- Use an old plastic container, like a bottle or an ice cream tub to collect the drained fluid
- Remove the brake fluid reservoir cap, and put the kit cap on instead
- Put the bottle down in the opening to the (car's) left of the reservoir, just behind the induction filter (unless you have some other induction kit fitted)
- Open the flip valve and watch the magic do its work