Clutch Pedal Assembly: Service and Repair

COMPONENTS






REPLACEMENT

1. Disconnect the connector of the ignition lock switch.
2. Remove the split pin (C) connecting the mater cylinder's push rod (A) and the clutch pedal's arm (B).




3. Remove the clutch pedal mounting bolts.
4. Remove the clutch pedal.
5. Install a new clutch pedal.
6. Install the clutch pedal mounting bolt and nut.

TORQUE: 24.5-34.3 Nm (250-350 kgf.cm, 18.1-25.3lb-ft)

7. Grease the clutch pedal mounting bolt and bushing of the turn-over spring.
8. Connect the connector of the ignition lock switch.
9. Adjust the clutch pedal and the ignition lock switch.

INSPECTION

1. Check the pedal shaft and bushing for wear.
2. Check the clutch pedal for bending or torsion.
3. Check the return spring for damage or deterioration.
4. Check the pedal pad for damage or wear.

Ignition lock switch inspection









RETURING TEST OF CLUTCH PEDAL
Deformation of pedal pad must be MAX. 5mm after repeating the test 20 times (sudden return from full stroke).

ADJUSTMENT

NOTE:
a. Check for the ignition lock switch.
In case of clutch lock system vehicle, there is an additional switch.
b. Before adjusting, remove the driver's floor seat.

1. After loosening the ignition lock switch nut, move it back until it has no contact with the clutch pedal arm.(In case of clutch lock system vehicle, repeat this step with its additional ignition lock switch).
2. Check for the specification below.

Specification: Clutch pedal stroke(A) - 145mm (5.7087in) / Clutch pedal free play(B) - 13mm (0.5118in) / Clutch pedal distance(C) - 234.7mm (9.2401in




3. (Clutch lock system vehicle)
Fix the additional ignition lock switch when its signal is ON pressing the pedal slowly 112-118 mm (4.4-4.6 in).
Tighten the bolts in the specified pattern.

TORQUE: 8-10Nm (0.8-1.0kgf.m, 5.9-7.4lb-ft)