Clutch Pedal Assembly: Service and Repair

Clutch Pedal Replacement (CTS)

Removal Procedure
1. Remove the driver side instrument panel insulator.
2. Disconnect the clutch pedal position switch electrical connector.





3. Disconnect the clutch master cylinder push rod from the clutch pedal pin.





4. Remove the clutch fluid reservoir attaching bolt.
5. Position the clutch fluid reservoir aside.
6. Remove the coolant surge tank and the vacuum brake booster.





7. Important: Do NOT disconnect the hydraulic hoses from the clutch master cylinder.

Rotate the clutch master cylinder clockwise 1/8 turn.
8. Remove the clutch master cylinder from the cowl.
9. Remove the park brake pedal assembly from the instrument panel and position aside.
10. Remove the wiring harness retainers from the clutch pedal assembly.





11. Remove the 2 bolts (2) securing the clutch pedal assembly to the instrument panel carrier.
12. Remove the 2 nuts (1) securing the clutch pedal assembly to the brake pedal assembly.
13. Remove the nut (3) securing the clutch pedal assembly to the cowl.
14. Remove the clutch pedal assembly from the vehicle.

Installation Procedure





1. Install the clutch pedal assembly to the vehicle.
2. loosely install the nuts (1), bolts (2), and nut (3) in order to align the clutch pedal assembly.

3. Notice: Refer to Fastener Notice in Service Precautions.

Tighten the clutch pedal fasteners in the following order.
1. Tighten the nuts (1).
Tighten the nuts to 20 Nm (15 ft. lbs.).

2. Tighten the bolts (2).
Tighten the bolts to 20 Nm (15 ft. lbs.).

3. Tighten the nut (3)
Tighten the nut to 9 Nm (80 inch lbs.).

4. Install the wiring harness retainers to the clutch pedal assembly.
5. Install the park brake pedal assembly.





6. With the clutch fluid reservoir connection at 2:00 position. Insert the clutch master cylinder into the cowl.
7. Align the keys of the clutch master cylinder housing with the tabs on the clutch pedal bracket.
8. Rotate the clutch master cylinder counter clockwise approximately 1/8 turn until fully seated. The clutch fluid reservoir hose connection will be at vertical 12:00 position when the clutch master cylinder is properly installed.
9. Install the vacuum brake booster and the coolant surge tank.





10. Install the clutch fluid reservoir.
11. Install the clutch fluid reservoir attaching bolt.

Tighten the bolt to 36 Nm (27 ft. lbs.).





12. Position the clutch master cylinder push rod to the clutch pedal pin.
13. Push the clutch master cylinder push rod onto the clutch pedal pin to secure.
14. Connect the clutch pedal position switch electrical connector.
15. Check for proper clutch pedal movement and operation.
16. Install the driver side instrument panel insulator.