Clutch Pedal Assembly: Service and Repair

REMOVAL PROCEDURE

IMPORTANT: Before removing the clutch pedal shaft arm from the clutch pedal shaft, place a reference mark on the clutch pedal shaft and clutch pedal shaft arm to ensure the correct assembly. If the clutch pedal shaft arm is installed in a position other than the one from which it was removed, the clutch release lever travel will increase or decrease resulting in a misadjusted clutch pedal.





1. Remove one nut (1), one bolt (1) and the clutch pedal shaft arm (2) from the clutch pedal shaft (3).





2. Remove the clutch pedal return spring (1) from the brake pedal bracket (2).





3. Push the clutch pedal (2) in to clear the Electronic Brake Control Module (EBCM) (1) and slide the clutch pedal (2) to the left (if equipped).





4. Remove the clutch pedal (11), clutch pedal return spring lever (8) and the clutch pedal return spring (10) from the brake pedal bracket (12).
5. Remove the clutch pedal shaft bushings (1) from the brake pedal bracket (2).
6. Inspect the clutch pedal shaft (9) and clutch pedal shaft bushings (1) for excessive wear. Replace as necessary.
7. Inspect the clutch pedal lever for distortion or bending. Replace as necessary.
8. Inspect the clutch pedal return spring (10) for distortion or weakness. Replace as necessary.

INSTALLATION PROCEDURE





1. Install the clutch pedal shaft bushings (1) into the brake pedal bracket (2).
2. Apply a thin coat of lithium grease to the inside of the clutch pedal shaft bushings (1).
3. Install the clutch pedal (11), the clutch pedal return spring lever (8) and the clutch pedal return spring (10) into the brake pedal bracket (2).





4. Install the clutch pedal return spring (1) to the brake pedal bracket (2).





5. Install the clutch pedal shaft arm (2) onto the clutch pedal shaft aligning index marks made during removal; secure with one bolt (1) and one nut (1).
^ Tighten the clutch pedal shaft arm bolt and nut to 24 Nm (17 ft. lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.

IMPORTANT: For clutch adjustment procedures, refer to Clutch Pedal Height Adjustment and Clutch Pedal Free Travel Adjustment.