Clutch Pedal Assembly: Service and Repair

Clutch Pedal

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





5. Remove the clevis pins which secure lever to push rod and operating rod.





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

INSTALLATION
1. Install in the reverse order of removal.
Tightening torque:
T: 18 Nm (1.8 kgf-cm, 13.0 ft. lbs.)

CAUTION: Always use a new clevis pin.

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 and rod S. and then remove the spring and bushing S.
6. Remove the stoppers from clutch pedal.
7. Remove the clutch pedal pad.

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

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

INSPECTION

CLUTCH PEDAL





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

NOTE:
^ Measure the length between the seat cushion front end and center portion of clutch pedal.
^ Slide the seat at seventh notch from the first notch.

Specified clutch pedal full stroke A:
Non-turbo model: 130-135 mm (5.12-5.31 inch)
Turbo model: 135-140 mm (5.31-5.51 inch)
2. If the clutch pedal stroke is out of specification, loosen the clutch switch lock nut to adjust.
Tightening torque (Clutch switch lock nut): 8 Nm (0.8 kgf-cm, 5.8 ft. lbs.)





3. Loosen the push rod lock nut.





4. Turn the push rod to adjust.
1. Ensure that the clutch pedal contacts clutch switch, when releasing the clutch pedal.
2. Ensure that the clutch pedal contacts clutch pedal bracket stopper, when fully depressing the clutch pedal.





5. Turn the push rod counterclockwise to shorten until clearance is made at clutch switch.
6. Turn the push rod clockwise to lengthen until clutch pedal contacts to clutch switch.





7. Turn the push rod further 270° counterclockwise to shorten (arrow direction as shown in the figure).
8. Move the clevis pin in lateral direction to ensure it moves smoothly.
9. Tighten the push rod lock nut.
Tightening torque: 10 Nm (1.0 kgf-cm, 7.2 ft. lbs.)
10. Depress and release the clutch pedal two or three times to ensure that clutch pedal and release fork operate smoothly. If the clutch pedal and release fork do not operate smoothly, bleed air from the clutch hydraulic system.
11. 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:
Non-turbo model: 130-135 mm (5.12-5.31 inch)
Turbo model: 135-140 mm (5.31-5.51 inch)
12. 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.





13. 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 the fluid level does not increase or push rod does not retract, replace the master cylinder with a new one.





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





17. 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