2010 Fusion clutch and brake pedal slow return.

[snopro879]

Hello!

 

So I just picked up a 2010 Fusion with 100k miles on it, 2.5L engine, and 6 speed manual. I love the car so far but have noticed one strange issue...

 

The clutch felt kind of...stiff, right off the bat. I figured eh, with 100k miles it might need a new clutch in near future, no big deal. But then I also noticed that when I let off the clutch pedal quickly, it feels like it's slow to actually return. This is the newest car I've ever owned, so I kinda guessed maybe it was some like anti-dump-able clutch valving in the slave cylinder or something that would control/slow down clutch engagement.

 

But then, I noticed a weird thump noise when letting off the brakes at times. I realized the brake pedal is also slow to return, and that the thump is the pedal hitting the stop upon it's return with my foot completely off the pedal. But, the brakes do not feel stiff at all like my interpretation of the clutch pedal when depressing.

 

SO! I've done a couple searches and have come up with nothing. Also seems that a 2010 fusion with a stick is a rarity. So here I am, asking for any help that might be available. My mechanically inclined mind is thinking something with the brake booster might be causing this issue? If it was brake fluid related I would imagine there would be other brake related problems, and besides the pedal return being slow, the brakes feel spot on. The vacuum booster is the only other component that I can think of that relates to both the brakes and clutch. Unless the pedal mechanism itself is somehow messed up? But I can't logically think of anything with the pedal mechanism that makes any sense for the symptom...unless they share a return mechanism of some sort which I doubt.

 

The weather here has had highs in the single digits, so I could understand a little bit different feeling, but not this drastic. Any tips or related fixes would be GREATLY appreciated!

 

Thank you so much!

-Corey-

[FusionDiffusion]

Have you checked the brake fluid level and condition? Both the brakes and clutch share the same fluid reservoir. Here is a notice from the service manual:

 

NOTICE: The clutch hydraulic system fluid is separated from the brake system fluid by a separate reservoir within the brake reservoir. Do not allow the clutchhydraulic system fluid level in the reservoir to fall more than 6 mm (0.236 in) below the MAX mark during the bleeding operation or fluid supply to the clutch release system will be starved, allowing air to enter the clutch master cylinder. Keep the brake master cylinder reservoir filled with clean, specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system.

 

If the fluid level in the master cylinder reservoir is more than 6 mm below the max mark, it is possible that the clutch reservoir within was starved for fluid, and you might have air in the system. I would recommend a clutch and brake bleed. If the fluid level is low you have worn brake or a leak in one of the two systems.

 

The speed the clutch master cylinder returns will be limited by the flow of brake fluid through the tube between the master and slave clutch cylinders. It is a fairly small tube so it might take a couple seconds. The clutch petal itself is returned by a spring, and the rod that connects it to the master cylinder is not connected so it can return immediately (the rod can only push, not pull back on the master clutch cylinder). The pedal should physically return fully immediately after you take your foot off it, but you might feel a dead zone in the pedal while the master cylinder returns if you happen to press it again a short time later.

 

FYI the clutch pedal travel should be 140 mm and the free play 1.0-3.0 mm.

Edited January 9, 2018 by FusionDiffusion

[snopro879]

" The pedal should physically return fully immediately after you take your foot off it, but you might feel a dead zone in the pedal while the master cylinder returns if you happen to press it again a short time later. "

 

Yes, I definitely feel a dead zone. I've just never driven a manual before that exhibited this. Between the early model escorts, focuses, even 5 speed trucks (both Ford and Dodge) that I've owned, I've never had a clutch pedal with a dead spot upon applying and releasing back to back. And to have the brake pedal do the same thing (though I don't feel a dead spot really) kind of worries me. My 2004 PZEV Focus has a cheapo Duralast slave in it (leaking on my carpet when I bought the car) and it I can pump that thing as fast as I physically can and the pedal never leaves my foot.

 

 

I checked the brake fluid level when I was inspecting the Fusion upon purchase. I'll revisit the reservoir to make sure it's full, even though I think that low fluid in the reservoir would lead to a spongy pedal, not a...lazy one. It's also supposed to be nearly 50 degrees this Thursday so I'll drive it and see if the temperature had anything to do with it.

 

At 100k miles, I don't see how a brake fluid flush could do any harm. Maybe I'll attempt that, along with bleeding the clutch system, and report back if it had any effects. Thanks for the reply! 

[FusionDiffusion]

It's possible there's air in the clutch system. Since the clutch isn't being pressed against a hard stop like brakes are, it would be much harder to detect air in the system. The other possibility is that you have some kind of restriction in the hydraulic system or hose to the reservoir that is slowing the movement of fluid down. Clutch bleed would be my first service action.