Clutch Pedal Assembly: Service and Repair
CLUTCH PEDALCOMPONENTS:
REMOVAL
1. REMOVE CLUTCH PEDAL SPRING
2. DISCONNECT CLUTCH MASTER CYLINDER PUSH ROD CLEVIS
a) Remove the clip and hole pin and disconnect the push rod clevis from the clutch pedal.
3. REMOVE CLUTCH PEDAL SUPPORT SUB-ASSEMBLY
a) Remove the 2 nuts, bolt and support.
DISASSEMBLY
1. REMOVE CLUTCH PEDAL SUB-ASSEMBLY
a) Remove the bolt and nut.
b) Remove the pedal from the clutch pedal support.
2. REMOVE CLUTCH PEDAL STOPPER BOLT
a) Loosen the lock nut and remove the bolt.
b) Remove the lock nut from the bolt.
3. REMOVE CLUTCH PEDAL PAD
4. REMOVE CLUTCH PEDAL BUSH
a) Remove the 2 bushes from the clutch pedal.
5. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH
a) Using an 8 mm hexagon wrench and hammer, tap out the clevis bush from the clutch pedal.
ADJUSTMENT
1. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY
a) Turn over the floor carpet.
b) Check that the pedal height is correct.
Standard pedal height from dash panel: 134.3 to 144.3 mm (5.287 to 5.681 inch)
c) Adjust the pedal height.
1) Loosen the lock nut and turn the stopper bolt until the correct height is obtained.
2) Tighten the lock nut.
Torque: 18 Nm (186 kgf-cm, 13 ft. lbs.)
2. INSPECT AND ADJUST PEDAL FREE PLAY AND PUSH ROD PLAY
a) Check that the pedal free play and push rod play are correct.
1) Depress the pedal until clutch resistance begins to be felt.
Standard pedal free play: 5.0 to 15.0 mm (0.197 to 0.591 inch)
2) Gently depress the pedal until the resistance begins to increase a little.
Standard push rod play at pedal top: 1.0 to 5.0 mm (0.039 to 0.197 inch)
b) Adjust the pedal free play and push rod play.
1) Loosen the lock nut and turn the push rod until correct free play and push rod play are obtained.
2) Tighten the lock nut.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
3) After adjusting the pedal free play, check the pedal height.
3. INSPECT AND ADJUST CLUTCH RELEASE POINT
a) Check the clutch release point.
1) Pull the parking brake lever and install wheel chocks.
2) Start the engine and run it at idle.
3) Without depressing the clutch pedal, slowly move the shift lever into reverse until the gears contact.
4) Gradually depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position.
Standard distance: 25 mm (0.98 inch) or more
(From pedal stroke end position to release point)
If the distance is not as specified, perform these operations.
^ Check pedal height.
^ Check push rod play and pedal free play.
^ Bleed air from clutch line.
^ Check clutch cover and disc.
REASSEMBLY
1. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH
a) Apply MP grease to the inside of a new bush.
b) Install the bush on the clutch pedal.
HINT: Install the bush from the left side of the vehicle.
2. INSTALL CLUTCH PEDAL BUSH
a) Apply MP grease to both sides of 2 new bushes.
b) Install the 2 bushes to the clutch pedal.
3. INSTALL CLUTCH PEDAL PAD
4. INSTALL CLUTCH PEDAL SUB-ASSEMBLY
a) Install the pedal on the clutch pedal support with the bolt and nut.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
HINT: Install the bolt from the left side of the vehicle.
5. INSTALL CLUTCH PEDAL STOPPER BOLT
a) Install the lock nut on the bolt but do not torque it.
b) Install the bolt so that its end touches the clutch pedal cushion.
HINT: Temporarily tighten the lock nut.
INSTALLATION
1. INSTALL CLUTCH PEDAL SUPPORT SUB-ASSEMBLY
a) Install the support on the vehicle with the 2 nuts and bolt.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
2. CONNECT CLUTCH MASTER CYLINDER PUSH ROD CLEVIS
a) Apply MP grease to the contact surface of the pin and clevis bush.
b) Connect the clevis to the clutch pedal with the pin and clip.
HINT: Install the pin from the left side of the vehicle.
3. INSTALL CLUTCH PEDAL SPRING
4. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY
a) Inspect and adjust the clutch pedal.