Clutch Pedal Assembly: Service and Repair

Clutch Pedal

REMOVAL

1) Disconnect the ground cable from battery.
2) Remove the steering column.
3) Disconnect the connector from the stop light switch and clutch switch.
4) Remove the snap pins from clevis pins which secure the lever to the push rod and operating rod.
5) Pull out the clevis pins which secures the lever to the push rod and operating rod.





6) Remove the air intake boot assembly.
7) Remove the nut which secures the clutch master cylinder.





8) Remove the bolts and nuts which secure the brake pedal and clutch pedal, and remove the pedal assembly.

INSTALLATION

1) Install in the reverse order of removal.

CAUTION:
Always use a new clevis pin.

2) Adjust the clutch pedal after installation.
3) Adjust the clutch switch.

DISASSEMBLY

1) Remove the clutch switches.
2) Remove the clip, assist spring, assist rod A, assist rod B, assist bushing, clutch clevis pin and bushing.





3) Remove the spring pin and lever.





4) Remove the clutch pedal and pedal bushings.





5) Remove the stopper and clutch pedal pad from the clutch pedal.





ASSEMBLY

1) Attach the stopper and pedal pad to the clutch pedal.
2) Install the clutch switch to the pedal bracket.
3) Clean the pedal bushing holes of the clutch pedal and the brake pedal, apply grease, and install the pedal bushings.
4) Install the clutch pedal, brake pedal and lever to the pedal bracket, and fix with a spring pin.
5) Install the assist rod A, assist rod B, assist bushing and assist spring to the clutch pedal and pedal bracket.

INSPECTION

Move the clutch pedal in the lateral direction with a force of approximately 10 N (1 kgf, 2 lbf) to check that the clutch pedal deflection is within the service limit.

CAUTION:
If the deflection exceeds the service limit, replace the clutch pedal assembly with a new part.

Deflection of the clutch pedal:
Service limit
4.0 mm (0.157 in) or less





ADJUSTMENT

1) If the full stroke of the clutch pedal is not within the specified value, loosen the lock nuts of the clutch switch and adjust the full stroke of the clutch pedal with the clutch switch.

CAUTION:
When adjusting the full stroke of clutch pedal, do not turn the clutch switch.

NOTE:
If the clutch switch cannot adjust the full stroke of clutch pedal to the specified value, adjust it by turning the master cylinder push rod.

Clutch pedal full stroke A:
130 - 135 mm (5.12 - 5.31 in)

Tightening torque:
T: 8 Nm (0.8 kgf-m, 5.9 ft-lb)





2) Loosen the push rod lock nuts of the master cylinder.





3) Rotate the push rod to adjust.





4) Make sure that the clutch pedal contacts the clutch pedal bracket stopper when the clutch pedal is at the maximum stroke position.
5) Make sure that the clutch pedal contacts the clutch switch side when the pedal is released.
6) Turn the push rod to shorten until a clearance is gained on the clutch switch side.





7) Turn the push rod to lengthen until clutch pedal contacts the clutch switch.
8) Turn further in the direction that will shorten the push rod by 270°.





9) Check that the clevis pin moves smoothly by moving it in the left and right directions.
10) Tighten the push rod lock nut of the master cylinder.

Tightening torque:
T: 10 Nm (1.0 kgf-m, 7.4 ft-lb)





11) Depress and release the clutch pedal two or three times to ensure that the clutch pedal and release lever operate smoothly. If the clutch pedal and release lever do not operate smoothly, bleed air from the clutch hydraulic system.
12) Measure the clutch pedal full stroke length again to ensure that it is within specifications. If it is not within specifications, repeat adjustment procedures again from the beginning.

Clutch pedal full stroke:
130 - 135 mm (5.12 - 5.31 in)

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





14) Push the release lever until the operating cylinder push rod retracts. Check that the clutch fluid level in the 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, readjust the clutch pedal.
17) Check the clutch fluid level using the scale on the outside of the reservoir tank. If the clutch fluid level is below "MIN", fill the clutch fluid up to "MAX" level.

Recommended clutch fluid:
New FMVSS No. 116 DOT3 or DOT4