Clutch Cable: Service and Repair

Clutch cable, removing and installing
(5-Speed Manual Transmission 020)

When the clutch cable is removed and installed, the adjusting mechanism must be tensioned using the same retaining strap used to compress the adjusting mechanism of a new cable. The strap is included with a new cable.






- Remove retaining strap from new cable by carefully cutting eyelet open at perforation (arrow).

Removing

CAUTION!
Do not kink the clutch cable, otherwise the adjusting mechanism may not function properly.

- Depress clutch pedal down to stop at least 5 times.






- Attach retaining strap so that eyelet (arrow -1-) is above protective boot.

- Compress adjusting mechanism in area of protective boot.

Note:
If the adjusting mechanism cannot be compressed, it is faulty.






- Hook tabs of retaining strap onto pins (arrow -2-) of adjusting mechanism (second technician required).

- Disconnect clutch cable attachment components from release shaft lever.

- Remove over-center spring.

- Disconnect clutch cable from clutch pedal and remove cable.

Installing

- Lubricate clutch cable mounting point at clutch pedal with MoS2grease.






- Pass clutch cable through bulkhead and suspend in front recess of clutch pedal, while making sure support plate (arrow) is installed on clutch cable.

Clutch cable tensioned

- Route clutch cable end piece through bracket on transmission and through release shaft lever.

CAUTION!
Be careful to not damage the plastic sleeve on the clutch cable.






- Connect attachment parts to release shaft lever and clutch cable (shown here on vehicle without balance weight).

- Hook clutch cable into wire retainers.

- Remove retaining strap in such a way that it can be used again.

- Install over-center spring.

- Depress clutch pedal down to stop at least 5 times.

- Check operation of clutch cable adjusting mechanism.

Balance weight modification






Beginning August, 1993, a balance weight will be attached to the clutch release lever in cases where excessive noise and vibration are transferred to the clutch pedal.

- The 200 gram balance weight installed on vehicles with 1.9 liter diesel engine (up to August 1993) is discontinued.

- Tightening torque: 25 Nm (18 ft lb)

Note:
The new balance weight can be installed on current vehicles as necessary to address complaints about clutch pedal noise and vibration.

Clutch cable not tensioned






- Mount retaining strap -A- above dust boot.

- Connect clutch cable to clutch pedal.

- Pull cable end piece in direction of arrow -1-, hold in place, and move adjusting mechanism -B- back and forth several times until it can be pressed together in direction of bulkhead (arrow -2-).

- Hold adjusting mechanism in compressed state and hook retaining strap tabs onto pins -C- on adjusting mechanism (second technician required).

- Connect clutch cable at transmission.

- Install over-center spring.

- Remove retaining strap.

- Check operation of adjusting mechanism.

Note:
No other cable (e.g. accelerator pedal cable, etc.) is to be attached to the clutch cable. The clutch cable adjusting mechanism may stop functioning.