CLUTCH PEDAL(for RHD) REMOVAL

PROCEDURE

1. REMOVE UPPER INSTRUMENT PANEL SUB-ASSEMBLY

   Click here

2. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY

   Click here

3. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS WITH HOLE PIN

   
   
   1. 

      Text in Illustration

      *A	for 2WW
      *B	for 1WW

      Remove the clip and clutch master cylinder push rod clevis with hole pin.

4. REMOVE CLUTCH PEDAL SUPPORT SUB-ASSEMBLY

   
   

   1. Disconnect the clutch start switch assembly connector and brake pedal stroke sensor assembly connector.

   2. 

      Remove the 2 nuts, 2 bolts and clutch pedal support sub-assembly.

5. REMOVE BRAKE PEDAL STROKE SENSOR ASSEMBLY (CLUTCH PEDAL STROKE SENSOR)

   Click here

6. REMOVE CLUTCH START SWITCH ASSEMBLY

   

   
   

   1. Remove the nut and clutch start switch assembly.

7. REMOVE CENTER OVER SPRING CAP

   

   
   

   1. Using a needle-nose pliers, remove the center over spring cap from the clutch pedal sub-assembly.

8. REMOVE TURN OVER SPRING SEAT COMPRESSION SPRING

   

   
   

   1. While the clutch pedal is fully depressed, remove the turn over spring seat compression spring.

      CAUTION:

      As the clutch pedal may move suddenly when removing the spring, be careful to prevent your hand from being caught in the parts.

9. REMOVE CLUTCH PEDAL SPRING HOLDER

   

   
   

   1. Remove the clutch pedal spring holder from the clutch pedal support sub-assembly.

10. REMOVE CLUTCH PEDAL STOPPER BOLT

    
    

    1. 

       Loosen the lock nut and remove the clutch pedal stopper bolt together with the nut from the clutch pedal support sub-assembly.

11. REMOVE CLUTCH PEDAL SPRING

    
    

    1. 

       Remove the clutch pedal spring.

12. REMOVE NO. 1 PEDAL SPRING HOOK

    

    
    

    1. Remove the No. 1 pedal spring hook from the clutch pedal support sub-assembly.

13. REMOVE CLUTCH PEDAL SUB-ASSEMBLY

    
    

    1. 

       Remove the bolt and nut.

    2. Remove the clutch pedal sub-assembly from the clutch pedal support sub-assembly.

14. REMOVE CLUTCH PEDAL PAD

    
    

    1. Remove the clutch pedal pad from the clutch pedal sub-assembly.

15. REMOVE CLUTCH PEDAL BUSHING

    

    
    

    1. Remove the 2 clutch pedal bushings and clutch pedal shaft collar from the clutch pedal sub-assembly.

16. REMOVE NO. 1 CLUTCH PEDAL CUSHION

    
    

    1. 

       Using a needle-nose pliers, remove the 2 No. 1 clutch pedal cushions from the clutch pedal sub-assembly.

17. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSHING

    
    

    1. 

       Using an 8 mm hexagon wrench and hammer, remove the clutch master cylinder push rod clevis bushing from the clutch pedal sub-assembly.

18. REMOVE CLUTCH PEDAL TURNOVER BUSH

    

    
    

    1. Remove the clutch pedal turnover bush from the clutch pedal sub-assembly.