Neutral Safety Switch: Service and Repair
CLUTCH INTERLOCK/UPSTOP SWITCHREMOVAL
LHD
1. Disconnect and isolate battery negative cable.
2. Remove left lower instrument panel bezel (Fig. 12).
3. Disconnect upstop switch and brake lamp switch connectors.
4. Disconnect clutch master cylinder rod from clutch pedal pin. Inspect plastic retainer upon removal. If retainer is damaged, it MUST be replaced.
5. Remove brake booster push rod retaining clip from brake pedal. Disengage rod from pedal (Fig. 13).
6. Remove two pedal assembly bracket to instrument panel nuts (Fig. 14).
7. Remove four brake booster/pedal bracket-to-cowl panel nuts (Fig. 14).
8. From under the hood, pull brake master cylinder/booster far enough forward to obtain pedal to bracket stud clearance.
9. Remove the pedal bracket assembly (Fig. 14).
10. Remove pedal pivot shaft and remove brake and clutch pedals.
11. Remove the interlock/upstop switch assembly (Fig. 15) from the brake/clutch pedal bracket assembly by depressing the four plastic wing tabs on each switch.
RHD
1. Disconnect the master cylinder push rod from the pedal pin (Fig. 16). Inspect push rod retainer for damage. If it is damaged (broken/cracked), it must be replaced.
2. Squeeze together the tangs on the switch cover plate and slide the plate off the switch housing.
3. Disconnect the clutch interlock/upstop switch connector from the instrument panel wiring harness.
4. Remove the switch from the vehicle.
INSTALLATION
LHD
NOTE: Proper switch harness routing is critical to switch durability. Note the harness routing and location of fasteners intended to keep wires from contacting pedals.
1. Install switches into the pedal bracket assembly as shown in (Fig. 15). Route harness as was prior to removal. Secure switch connector retaining push pin into the appropriate hole in the pedal bracket assembly
2. Install clutch and brake pedals to pedal bracket, and install pivot shaft and nut. Torque pivot shaft nut to 42 Nm (31 ft. lbs.).
3. Install brake/clutch pedal bracket assembly into position. Install and tighten brake booster mounting nuts to 34 Nm (25 ft. lbs.). Install and tighten pedal bracket-to-instrument panel nuts to 34 Nm (25 ft. lbs.).
4. Install new stop lamp switch.
5. Connect brake booster rod to brake pedal. Install retainer clip (Fig. 13).
6. Loosen adjustment screw (Fig. 17).
CAUTION: Inspect clutch master cylinder pushrod plastic retainer. If retainer is damaged in any way (broken/cracked) it MUST be replaced.
7. Connect clutch master cylinder pushrod. Gently lift clutch pedal upwards until the clutch pedal fully depresses the the upstop switch. Torque adjustment screw to 6 Nm (55 inch lbs.).
8. Connect interlock/upstop and stop lamp switch connectors.
9. Install left lower instrument panel bezel (Fig. 12).
10. Connect battery negative cable.
11. Verify proper switch operation.
RHD
NOTE: Proper switch harness routing is critical to switch durability. Note the harness routing and location of fasteners intended to keep wires from contacting pedals.
1. Install the clutch interlock/upstop switch onto the master cylinder push rod, making sure that the push rod is oriented with the push rod retainer toward the wiring of the switch. The master cylinder push rod must be snapped into the clutch interlock/ upstop switch along the smaller diameter of the push rod between the snap ring and the transition to the larger diameter.
CAUTION: Improper assembly of the larger diameter of the push rod into the clutch interlock/upstop switch could cause damage to the switch or a clutch system failure.
2. Install the switch cover plate.
CAUTION: Inspect the plastic push rod retainer for damage. If it is damaged (broken/cracked), it MUST be replaced.
3. Connect clutch master cylinder pushrod to the clutch pedal pin.
4. Route the wiring harness as it was prior to removal.
5. Secure the switch connector retaining push pin into the appropriate hole in the pedal bracket assembly.