Clutch Pedal - Excessive Freeplay
CATEGORYTransmission
SECTION PAGE
4 30
ISSUE CODE
09/95-0617 412
Subject: Correcting a Customer Complaint
Regarding Clutch Pedal Play
Application: 1994 900 Models with Manual Gearbox
On 1994 and later 900 models equipped with manual transmissions, customers may complain that their car has excessive clutch pedal play or a clutch that engages too early (when the pedal is close to the floor). The following procedure will resolve such a complaint.
Cars Affected:
1994 900 Models with Manual Gearbox
Parts:
Washer, 2mm 43 33 811
Molycote, l0g tube 8781 718
or silicone grease (source locally at marine supply stores)
Action 1:
1:
1. Pull the clutch lever forward 2-3 times (see item 1, Figure 1). Listen for squeaking or any other unwanted noise.
1:
2. Move the main fuse box out of the way (see item 3, Figure 2). This will enable you to easily reach the return spring.
CAUTION
Jerking the return spring suddenly can damage the mechanism. In the next step, pull steadily on the return spring.
3. Pull the return spring forward, away from the bulkhead (see item 2, Figure 1), then release the spring.
NOTE:
Pulling the return spring forward relieves tension on the self-adjusting mechanism and allows it to index itself.
4. Check the free play in the clutch pedal. If it is 2Omm or less, no further adjustment is necessary. If pedal free play is greater than 2Omm, perform Action 2.
5. If you heard any squeaking or unwanted noise when you pulled the clutch lever forward in step 1 or while working the clutch pedal up and down, apply Molycote to the cable's plastic ring where it touches the clutch pedal.
6. Move the main fuse box back in place.
Action 2:
NOTE:
Complete this action only if clutch pedal free play is greater than 2Omm.
1. Remove the clutch cable as described in Service Manual 4:1 'Manual gearbox," pages 412-2 and 412-3.
2. Remove the self-adjusting device's rubber damper and move it over the plastic ring (see item 4, Figure 3).
3. Fit a washer, P/N 43 33 811, to the self-adjusting device (see item 5, Figure 3).
4. Refit the rubber damper.
5. If you heard any squeaking or unwanted noise when you pulled the clutch lever forward in Action 1, step 1, or while working the clutch pedal up and down, apply Molycote to the cable's plastic ring where it touches the clutch pedal.
6. Refit the clutch cable. Refer to Service Manual 4:1, "Manual gearbox," page 412-4.
7. Depress and release the clutch pedal five times.
8. Without jerking, pull the return spring forward, away from the bulkhead, and release it.
9. Recheck the free play in the clutch pedal. If it is more than 20mm, repeat Action 2.
10. Move the main fuse box back in place.
Warranty Information:
To resolve a customer complaint for a vehicle in warranty, submit a claim using the following information:
Action 1: Adjust cable and check free play:
Failure code: 41281-71-0-01-05
Straight time: 0.2
Action 2: Adjust cable, check free play, fit washer, and R&R clutch cable:
Failure code: 41281-71-0-01-05
Labor operation 41281: 0.5
Straight time: 0.4