Clutch Pedal Assembly: Service and Repair

Clutch Pedal Replacement

Removal Procedure

1. Disable the SIR system. Refer to SIR Disabling and Enabling (Service and Repair).
Warning: Refer to Battery Disconnect Warning (Battery Disconnect Warning).

2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).





Note: Do not fully remove the hydraulic clutch hose/pipe retaining clip (5) from the clutch master cylinder (4).

3. Release the hydraulic clutch hose/pipe retaining clip (5) from the clutch master cylinder (4).
4. Disconnect the hydraulic clutch hose/pipe (1) from the clutch master cylinder (4).

Note: Ensure the rubber seal is attached to the reservoir (not on the master cylinder).

5. Pull the clutch master cylinder reservoir hose (2) from the clutch master cylinder (4).
6. Remove the clutch pedal to mod plate retaining nuts (3).
7. Remove the instrument panel lower trim panel assembly. Refer to Instrument Panel Insulator Panel Replacement - Right Side (LHD) (Service and Repair).
8. Remove the instrument panel lower trim panel retainer. Refer to Instrument Panel Retainer Replacement (Service and Repair).




9. Disconnect the clutch pedal wiring harness (1) from the cockpit wiring harness (2).
10. Remove the clutch pedal to instrument panel cross member retaining bolts (3).
11. Lower and remove the clutch pedal assembly (4).

Installation Procedure




1. Install the clutch pedal assembly (4) to the vehicle.





Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the clutch pedal to mod plate retaining bolts (3) and tighten to 22 Nm (16 lb ft).

Note: Listen for an audible click to confirm fitting.

3. Push fit the hydraulic clutch hose/pipe (1) to the clutch master cylinder (4).
4. Connect the clutch pedal wiring harness (1) to the cockpit wiring harness (2).
5. Install the instrument panel lower trim panel retainer. Refer to Instrument Panel Retainer Replacement (Service and Repair).
6. Install the instrument panel lower trim panel assembly. Refer to Instrument Panel Insulator Panel Replacement - Right Side (LHD) (Service and Repair).
7. Connect the clutch master cylinder reservoir hose (2), by firmly pushing it on to the clutch master cylinder (4).
8. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding (Service and Repair).
9. Enable the SIR system. Refer to SIR Disabling and Enabling (Service and Repair).
10. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
11. Road test vehicle for correct clutch operation.