Revision as of 14:18, 11 October 2008

Introduction

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.

Tools

• 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.

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):

1. Undoing the first nut at the loose end of the clear hose
2. Remove the first of the two washers, and make sure the second one stays on the threaded piece of metal tubing
3. Put the cap that fits onto the threads, with the hose coming out the outside of it
4. Put the first washer back on to the tubing, which is now inside the cap
5. Put the nut back on to the tubing, and tighten up on both sides of the cap

Testing the kit

Test the kit if you haven't done that already, as you want to know that it can handle the pressure:

• 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.

Method

1. Bring the spare tyre out, and put it down in front of the car
2. Pop the hood, and locate the following components:
   • Brake fluid reservoir
   • Clutch bleeder valve
3. Fill the bottle in the kit with clean brake fluid, DOT4, and screw its cap on.
4. Assemble the clear hose with the cap from the kit that fits the Mondeo's reservoir
5. Connect the black hose to the spare tyre
6. In the kit, there's another clear hose. Undo the cap on the clutch bleeder valve, and connect that hose to it.
7. Use an old plastic container, like a bottle or an ice cream tub to collect the drained fluid.
8. Hold the bottle upside down, and open the valve.

WORK IN PROGRESS

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