CLUTCH PEDAL INSTALLATION

INSTALL CLUTCH PEDAL PAD
1. Install the clutch pedal pad to the clutch pedal sub-assembly.

INSTALL NO. 2 CLUTCH PEDAL CUSHION

Apply MP grease to the inner surface of a new No. 2 clutch pedal cushion.

Text in Illustration

MP grease

Note

Do not allow grease to adhere to the rubber part of the No. 2 clutch pedal cushion.

Text in Illustration
	MP grease

Text in Illustration
*a	Flange of Bush
*b	1.0 mm (0.0394 in.)

Using SST and a press, install the No. 2 clutch pedal cushion to the clutch pedal sub-assembly.

Tech Tips

Check that the outer casing of the No. 2 clutch pedal cushion is positioned as shown in the illustration

SST: 09316-60011 ( 09316-00061 ); 09623-30011

Tech Tips

Install the No. 2 clutch pedal cushion so that the flange of the bush is facing the left side of the vehicle.

INSTALL NO. 1 CLUTCH PEDAL CUSHION
1. Install the 3 No. 1 clutch pedal cushions to the clutch pedal sub-assembly.
INSTALL CLUTCH PEDAL SHAFT COLLAR
1. Apply MP grease to both sides of 2 new clutch pedal bushes.
  
  Text in Illustration
  
  MP grease
2. Install the 2 clutch pedal bushes and clutch pedal shaft collar to the clutch pedal sub-assembly.
INSTALL CLUTCH PEDAL SPRING
1. Apply MP grease to the inner surface and hook of the clutch pedal spring.
  
  Text in Illustration
  
  MP grease
2. Install the clutch pedal spring to the clutch pedal sub-assembly.
INSTALL CLUTCH PEDAL SUB-ASSEMBLY
1. Install the clutch pedal sub-assembly to the clutch pedal bracket sub-assembly with the bolt and nut.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  
  Note
  
  Turn the nut while holding the bolt.
2. Connect the clutch pedal spring to the clutch pedal bracket sub-assembly.
INSTALL CLUTCH PEDAL STOPPER BOLT
1. Install the clutch pedal stopper bolt to the clutch pedal bracket sub-assembly and temporarily install the lock nut.
  
  Tech Tips
  
  Tighten the lock nut to the specified torque when adjusting the clutch pedal.

Text in Illustration
	MP grease

Text in Illustration
	MP grease

INSTALL CLUTCH PEDAL STROKE SENSOR ASSEMBLY

Text in Illustration
*1	Arm
*2	Rod
*a	Alignment Mark

Insert the clutch pedal rod into the clutch pedal stroke sensor assembly.

Align the clutch pedal stroke sensor assembly with the alignment marks on the clutch pedal bracket.
Attach the clamp and install the clutch pedal stroke sensor assembly with the 2 nuts.

Torque:

8.5 N*m { 87 kgf*cm, 75 in.*lbf }

INSTALL CLUTCH WITH AIR CLEANER BOOSTER ASSEMBLY
1. Install the clutch with air cleaner booster assembly to the clutch pedal bracket sub-assembly with the 4 nuts.
  
  Torque:
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS
1. Install a new clip, hole pin and clutch master cylinder push rod clevis to the clutch with air cleaner booster assembly.
INSTALL CLUTCH PEDAL BRACKET SUB-ASSEMBLY
1. Install the clutch pedal bracket sub-assembly to the pedal bracket sub-assembly with the 4 bolts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
INSTALL CLAMP
1. Install the 2 clamps.
INSTALL PEDAL BRACKET ASSEMBLY

Click here
CONNECT WIRE HARNESS CONNECTOR
1. Connect the clutch pedal stroke sensor connector.
INSTALL NO. 1 CLUTCH BOOSTER VACUUM HOSE
1. Install the No. 1 clutch booster vacuum hose with the 2 clamps.
2. Connect the No. 1 clutch booster vacuum hose, and slide the 2 clamps to secure it.
INSTALL INSTRUMENT PANEL SUB-ASSEMBLY

Click here
INSTALL CLUTCH MASTER CYLINDER ASSEMBLY

Click here
FILL RESERVOIR WITH BRAKE FLUID
1. Fill the reservoir with brake fluid.
  
  Fluid
  
  SAE J1703 or FMVSS No. 116 DOT 3
  
  Note
  
  Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
BLEED CLUTCH LINE

Tech Tips

See Pub. No. RM1008E, page 42-2.
INSPECT FOR FLUID LEAK
INSPECT FLUID LEVEL IN RESERVOIR
1. Check the fluid level and add fluid if necessary.
  
  Fluid
  
  SAE J1703 or FMVSS No. 116 DOT 3
INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY

Click here
INSTALL EXHAUST RETARDER SWITCH ASSEMBLY
1. Temporarily install the exhaust retarder switch assembly to the clutch pedal bracket sub-assembly with the nut.
  
  Tech Tips
  
  Perform the clutch pedal adjustment after installing the exhaust retarder switch assembly.
2. Text in Illustration
  
  *a Clearance
  
  Without depressing the clutch pedal, turn nut A and nut B as necessary to adjust the clearance shown in the illustration until it is within the specified range.
  
  Standard clearance
  
  0 to 1.0 mm (0 to 0.0393 in.)
3. Tighten nut A.
  
  Torque:
  
  24 N*m { 245 kgf*cm, 18 ft.*lbf }
4. Connect the exhaust retarder switch connector.
INSTALL POWER TAKE-OFF CLUTCH SWITCH ASSEMBLY
1. Temporarily install the power take-off clutch switch assembly to the clutch pedal bracket sub-assembly with the nut.
  
  Tech Tips
  
  Perform the clutch pedal adjustment after installing the power take-off clutch switch assembly.
2. Text in Illustration
  
  *a Clearance
  
  While depressing the clutch pedal, turn nut A and nut B as necessary to adjust the clearance shown in the illustration until it is within the specified range.
  
  Standard clearance
  
  1.0 to 3.0 mm (0.0394 to 0.118 in.)
3. Tighten nut A.
  
  Torque:
  
  24 N*m { 245 kgf*cm, 18 ft.*lbf }
4. Connect the power take-off clutch switch connector.
CLUTCH PEDAL STROKE SENSOR ZERO POINT CALIBRATION
1. If the clutch pedal stroke sensor has been replaced, perform clutch pedal stroke sensor zero point calibration and release position calibration Click here.