Clutch Pedal Assembly: Service and Repair

Clutch Pedal

REMOVAL
1) Remove the steering column.
2) Disconnect the connectors from stop light and clutch switches.
3) Remove the snap pins which secure lever to push rod and operating rod.





4) Remove the clevis pins which secure lever to push rod and operating rod.
5) Remove the air cleaner case and intake duct.
6) Remove intercooler. (Turbo model)





7) Remove the nut which secures clutch master cylinder.
8) Remove the bolts and nuts which secure brake and clutch pedals, and remove pedal assembly.

INSTALLATION
1) Install in the reverse order of removal.

CAUTION:
^ If the cable clamp is damaged, replace it with a new one.
^ Never fail to cover outer cable end with boot.
^ Be careful not to kink the accelerator cable.
^ Always use a new clevis pins.

2) Adjust the clutch pedal after installation.

DISASSEMBLY
1) Remove the clutch switches.





2) Remove the clips, assist spring, rod and bushing.





3) Remove the spring pin and lever.





4) Remove the clutch pedal and bushings.





5) Remove the stopper, clip, O-ring, rods and then remove the spring and bushing.
6) Remove the stoppers from clutch pedal.
7) Remove the clutch pedal pad. (Non-turbo model)

ASSEMBLY
1) Attach the clutch switch, etc. to pedal bracket temporarily.
2) Clean the inside of bores of clutch pedal and brake pedal, apply grease, and set bushings into bores.
3) Align the bores of pedal bracket, clutch pedal and brake pedal, attach brake pedal return spring, assist rods, and spring, and bushing.

NOTE: Clean up inside of bushings and apply grease before installing the spacer.

INSPECTION





Move the clutch pedal pads in the lateral direction with a force of approximately 10 N (1 kgf, 2 lbs.) to ensure the pedal deflection is in specified range.

CAUTION: If excessive deflection is noted, replace the bushings with new ones.

Deflection of clutch pedal:
Service limit 5.0 mm (0.197 inch) or less

ADJUSTMENT





1) Turn the lock nuts until clutch pedal full stroke length is within specifications.

CAUTION: Do not attempt to turn the clutch switch to adjust clutch pedal full stroke length.

NOTE: If the lock nuts cannot adjust the clutch pedal full stroke length to specifications, turn the master cylinder push rod to adjust it.

Specified clutch pedal full stroke:
A 130 - 135 mm (5.12 - 5.31 inch)
Tightening torque (Clutch switch lock nut):
T: 8 Nm (0.8 kgf-m, 5.8 ft. lbs.)





2) Turn the master cylinder push rod so that the clevis pin moves to the left and then to the right. Clevis pin must move without resistance while it is rattling.
Tightening torque (Push rod lock nut):
T: 10 Nm (1.0 kgf-m, 7 ft. lbs.)
3) Depress and release the clutch pedal 2 to 3 times to ensure that the clutch pedal and release fork operates smoothly. If the clutch pedal and release fork do not operate smoothly, bleed air from the clutch hydraulic system.
4) Measure the clutch pedal full stroke length again to ensure that it is within specifications. If it is not, repeat adjustment procedures again from the beginning.
Specified clutch pedal full stroke: 130 - 135 mm (5.12 - 5.31 inch)
5) Move the clevis pin to the left and then to the right. It should move without resistance while it is rattling. If resistance is felt, repeat adjustment procedures again from the beginning.





6) Push the release lever until operating cylinder push rod retracts. Ensure that the clutch fluid level in reservoir tank increases. If the clutch fluid level increases, hydraulic clutch is properly adjusted; if fluid level does not increase or push rod does not retract, replace the master cylinder with a new one.





7) Push the release lever until operating cylinder push rod retracts. Check that the clutch fluid level in reservoir tank increases.
8) If the clutch fluid level increases, hydraulic clutch play is correct.
9) If the clutch fluid level does not increase or push rod does not retract, clutch pedal must be readjusted.





10) Check the fluid level on the outside of the reservoir tank. If the level is below "MIN", add clutch fluid to bring it up to "MAX".
Recommended clutch fluid: FMVSS No. 116, fresh DOT 3 or DOT 4 brake fluid