Clutch Pedal Assembly: Service and Repair

CLUTCH PEDAL

COMPONENTS For TMC Made:

COMPONENTS For TMMK Made (Part 1):

COMPONENTS For TMMK Made (Part 2):

REMOVAL
1. PRECAUTION
Observe Restraint Systems; Service Precautions.
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE FRONT DOOR SCUFF PLATE LH
4. REMOVE COWL SIDE TRIM SUBASSEMBLY LH
5. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made)
6. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made)
7. REMOVE NO. 1 INSTRUMENT PANEL SUBASSEMBLY
8. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System)
9. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System)
10. REMOVE INSTRUMENT CLUSTER FINISH PANEL
11. REMOVE COMBINATION METER ASSEMBLY (for TMC Made)
12. REMOVE COMBINATION METER ASSEMBLY (for TMMK Made)
13. DISCONNECT CONNECTORS
(a) Disconnect the clutch start switch connector.
(b) Disconnect the clutch switch connector (with cruise control).





14. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS PIN
(a) Remove the clip and pin.





15. REMOVE CLUTCH PEDAL SUPPORT SUBASSEMBLY
(a) Remove the bolt, 2 nuts and clutch pedal support assembly.

16. REMOVE TORSION SPRING
(a) While the clutch pedal is fully depressed, remove the torsion spring.

17. REMOVE PEDAL WITH HOOK SPRING
(a) Remove the pedal with hook spring.





18. REMOVE CLUTCH PEDAL SUBASSEMBLY
(a) Remove the pedal shaft and nut.
(b) Remove the clutch pedal from the clutch pedal support.

19. REMOVE CLUTCH PEDAL SPRING HOLDER
(a) Remove the clutch pedal spring holder from the clutch pedal support.

20. REMOVE CLUTCH PEDAL PAD
(a) Remove the clutch pedal pad from the clutch pedal.





21. REMOVE CLUTCH PEDAL BUSHING
(a) Remove the 2 pedal bushings and pedal shaft collar from the clutch pedal.





22. REMOVE NO. 1 CLUTCH PEDAL CUSHION
(a) Using needle-nose pliers, remove the 2 No. 1 clutch pedal cushions from the clutch pedal.





23. REMOVE CLUTCH PEDAL TURNOVER BUSHING
(a) Remove the turnover bushing from the clutch pedal.





24. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSHING
(a) Using an 8 mm hexagon wrench and a hammer, remove the clevis bushing from the clutch pedal.

INSTALLATION





1. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSHING
(a) Apply MP grease to the inside of a new clevis bushing.
(b) Install the clevis bushing to the clutch pedal.

HINT: Install the clevis bushing from the left side of the vehicle.





2. INSTALL CLUTCH PEDAL TURNOVER BUSHING
(a) Apply MP grease to the inside of the turnover bushing.
(b) Install the turnover bushing to the clutch pedal.





3. INSTALL NO. 1 CLUTCH PEDAL CUSHION
(a) Using needle-nose pliers, install the 2 No. 1 clutch pedal cushions to the clutch pedal.





4. INSTALL CLUTCH PEDAL BUSHING
(a) Apply MP grease to the inner, outer and end surfaces of 2 new pedal bushings.
(b) Install the clutch pedal shaft collar and 2 pedal bushings to the clutch pedal.

5. INSTALL CLUTCH PEDAL PAD
(a) Install the clutch pedal pad to the clutch pedal.





6. INSTALL CLUTCH PEDAL SPRING HOLDER
(a) Apply MP grease to the inside of a new clutch pedal spring holder.
(b) Install the clutch pedal spring holder.





7. INSTALL CLUTCH PEDAL SUBASSEMBLY
(a) Install the clutch pedal to the clutch pedal support with the bolt and nut.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)

HINT: Install the bolt from the right side of the vehicle.





8. INSTALL PEDAL WITH HOOK SPRING
(a) Apply MP grease to the sliding portion of the spring.
(b) Install the hook spring.





9. INSTALL TORSION SPRING
(a) Apply MP grease to the sliding portion of the spring.
(b) Install the torsion spring.





10. INSTALL CLUTCH PEDAL SUPPORT SUBASSEMBLY
(a) Install the clutch pedal support to the vehicle with the 2 nuts and bolt.
Torque:
Bolt 19 Nm (195 kgf-cm, 14 ft. lbs.)
Nut 12 Nm (120 kgf-cm, 9 ft. lbs.)





11. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS PIN
(a) Apply MP grease to the contact surface of the pin and clevis bushing.
(b) Connect the clevis to the clutch pedal with the pin and a new clip.

HINT: Install the pin from the left side of the vehicle.

12. CONNECT CONNECTORS
(a) Connect the clutch start switch connector.
(b) Connect the clutch switch connector (with cruise control).

13. INSTALL COMBINATION METER ASSEMBLY (for TMC Made)
14. INSTALL COMBINATION METER ASSEMBLY (for TMMK Made)
15. INSTALL INSTRUMENT CLUSTER FINISH PANEL
16. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Smart Key System)
17. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/ Smart Key System)
18. INSTALL NO. 1 INSTRUMENT PANEL SUBASSEMBLY
19. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMC Made)
20. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL LH (for TMMK Made)
21. INSTALL COWL SIDE TRIM SUBASSEMBLY LH
22. INSTALL FRONT DOOR SCUFF PLATE LH
23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
24. INSPECT AND ADJUST CLUTCH PEDAL SUBASSEMBLY.