Clutch Pedal Assembly: Service and Repair

REMOVAL
1. Disconnect ground cable from battery.
2. Disconnect clutch cable from release lever.
3. Remove instrument panel lower cover from instrument panel.
4. Disconnect the following parts from pedal bracket.
a. Operating rod of brake booster
b. Electrical connectors (for top light switch, etc.)
5. Remove clevis pin which secures pedal to push rod.
6. Remove bolts and nuts which secure brake and clutch pedals, and remove pedal bracket and clutch cable as a unit.

CAUTION: Before removing clutch cable from toe board, remove grommet. Slowly remove clutch cable, being careful not to scratch it.

7. Depress clutch pedal, disconnect clutch cable from clutch pedal.






INSPECTION
Move brake and clutch pedal pads in the lateral direction with a force of approximately 10 N (2 lbs.). to ensure pedal deflection is in specified range.
Deflection of brake and clutch pedal: Service limit: 5.0 mm (0.197 inch) or less.

CAUTION: If excessive deflection is noted, replace bushings with new ones.

INSTALLATION





1. Installation is in the reverse order of removal procedures.
2. Attach stop light switch, etc. to pedal bracket temporarily.
3. Clean inside of bores of clutch pedal and brake pedal, apply grease, and set bushings into bores.
4. Align bores of pedal bracket, clutch pedal and brake pedal, attach brake pedal return spring and clutch pedal effort reducing spring (vehicle with hill holder), and then install pedal bolt.
Tightening Torque: T2: 29 +/-7 Nm (21.7 +/-5.1 ft. lbs.).

NOTE: Clean up inside of bushings and apply grease before installing spacer.





5. Set brake pedal position by adjusting position of stop light switch.
Pedal position L: 125.9 mm (4.96 inch).
Tightening Torque: T1: 8 +/-12 Nm (5.8 +/-1.4 ft. lbs.).


CAUTION:
- Be careful not to bend clutch cable too much.
- Never fail to cover outer cable end with boot.
- Be careful not to kink accelerator cable.
- Make sure that holder and casing cap are securely connected.





(1) Casing cap
(2) Accelerator cable
(3) Toe board
(4) Accelerator pedal bracket
(5) Holder
6. Adjustment after pedal installation.