Clutch Pedal Assembly: Service and Repair

CLUTCH PEDAL SUB-ASSY
REPLACEMENT
1. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSY
2. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN
a) Remove the clip and hole pin.
3. REMOVE CLUTCH PEDAL ASSY





a) Disconnect the clutch start switch connector.
b) Disconnect the clutch switch connector.
c) Remove the bolt, 2 nuts and clutch pedal assy.
4. REMOVE CLUTCH START SWITCH ASSY
a) Remove the nut and clutch start switch assy from the clutch pedal support.
5. REMOVE CLUTCH SWITCH ASSY
a) Remove the nut and clutch switch assy from the clutch pedal support.
6. REMOVE TURN OVER SPRING SEAT COMPRESSION SPRING





a) Using a small screwdriver, remove the E-ring.
b) Remove the compression spring and clutch pedal spring holder.
7. REMOVE CLUTCH PEDAL SUB-ASSY





a) Using a small screwdriver, remove the E-ring.
b) Remove the clutch pedal spring and pedal spring hook.
c) Mount the clutch pedal assy in a soft jaw vise.

NOTICE: Do not overtighten the vise.





d) Remove the bolt, nut and clutch pedal sub-assy from the clutch pedal support.
8. REMOVE CLUTCH PEDAL BUSH





a) Remove the 2 bushes from the clutch pedal sub-assy.





9. REMOVE CLUTCH PEDAL TURNOVER BUSH
10. REMOVE OVER CENTER SPRING CAP
11. REMOVE CLUTCH PEDAL PAD
12. REMOVE CLUTCH PEDAL NO.1 CUSHION
a) Remove the clutch pedal No.1 cushion from the clutch pedal sub-assy.
b) Remove the clutch pedal No. 1 cushion from the clutch pedal support sub-assy.
13. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH





a) Using a hexagon wrench (8 mm) and hammer, remove the clevis bush from the clutch pedal sub-assy.
14. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSH





a) Apply MP grease to the inside of a new bush.
b) Install the clevis bush to the clutch pedal sub-assy.

HINT: Install the clevis bush from the left side of the vehicle.

15. INSTALL CLUTCH PEDAL NO.1 CUSHION
a) Install the clutch pedal No. 1 cushion to the clutch pedal sub-assy.
b) Install the clutch pedal No. 1 cushion to the clutch pedal support sub-assy.
16. INSTALL CLUTCH PEDAL PAD





17. INSTALL OVER CENTER SPRING CAP
18. INSTALL CLUTCH PEDAL TURNOVER BUSH
a) Install a new bush to the clutch pedal sub-assy.
19. INSTALL CLUTCH PEDAL BUSH





a) Apply MP grease to both sides of 2 new bushes.
b) Install the 2 bushes to the clutch pedal sub-assy.
20. INSTALL CLUTCH PEDAL SUB-ASSY





a) Install the clutch pedal sub-assy to the clutch pedal sup port with the bolt and nut.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)

HINT: Install the bolt from the right side of the vehicle.





b) Install the clutch pedal spring and pedal spring hook.
c) Using needle nose pliers, install a new E-ring.
21. INSTALL TURN OVER SPRING SEAT COMPRESSION SPRING





a) Apply MP grease to the contact surface of the bush and spring.
b) Install the compression spring and clutch pedal spring holder.
c) Using needle nose pliers, install a new E-ring.
22. INSTALL CLUTCH START SWITCH ASSY
a) Install the clutch start switch assy to the clutch pedal support with the nut.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
23. INSTALL CLUTCH SWITCH ASSY
a) Install the clutch switch assy to the clutch pedal support with the nut.
Torque: 26 Nm (260 kgf-cm, 14 ft. lbs.)
24. INSTALL CLUTCH PEDAL ASSY
a) Install the clutch pedal assy with the bolt and 2 nuts.
Torque:
Bolt: 19 Nm (195 kgf-cm, 14 ft. lbs.)
Nut: 12 Nm (120 kgf-cm, 9 ft. lbs.)
b) Connect the clutch switch connector.
c) Connect the clutch start switch connector.
25. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN





a) Apply MP grease to the contact surface of the hole pin and bush.
b) Connect the clevis to the clutch pedal assy with the hole pin.

HINT: Install the hole pin from the left side of the vehicle.

c) Install the clip to the hole pin.
26. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSY
27. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSY
28. INSPECT CLUTCH START SWITCH ASSY