CLUTCH PEDAL(for RHD) ADJUSTMENT

PROCEDURE


  1. INSPECT AND ADJUST CLUTCH PEDAL


    1. A004JVFE02
      Text in Illustration
      *1 Lock Nut
      *a Pedal stroke

      If the full stroke of the clutch pedal sub-assembly is not within the specified value, loosen the lock nuts of the clutch switch assembly and adjust the full stroke of the clutch pedal sub-assembly with the clutch switch assembly.

      Pedal stroke
      110 to 115 mm (4.331 to 4.528 in.)
      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note

      When adjusting the full stroke of the clutch pedal sub-assembly, do not turn the clutch switch assembly.

      Tech Tips

      If the clutch switch assembly cannot adjust the full stroke of clutch pedal sub-assembly to the specified value, adjust it by turning the clutch master cylinder push rod.

    2. A004KIX

      Loosen the push rod lock nuts of the clutch master cylinder assembly.

    3. A004IILE01
      Text in Illustration
      *a In the Longer Direction
      *b In the Shorter Direction

      Rotate the clutch master cylinder push rod to adjust.

    4. Make sure that the clutch pedal sub-assembly contacts the clutch pedal stopper when the clutch pedal sub-assembly is at the maximum stroke position.

    5. Make sure that the clutch pedal sub-assembly contacts the clutch switch side when the pedal is released.

    6. A004HEM

      Turn the clutch master cylinder push rod to shorten until a clearance is gained on the clutch switch side.

    7. Turn the clutch master cylinder push rod to lengthen until clutch pedal sub-assembly contacts the clutch switch assembly.

    8. A004IILE01
      Text in Illustration
      *a In the Longer Direction
      *b In the Shorter Direction

      Turn further in the direction that will shorten the clutch master cylinder push rod by 270°.

    9. Check that the clevis pin moves smoothly by moving it in the left and right directions.

    10. A004KIX

      Tighten the clutch master cylinder push rod lock nut of the clutch master cylinder assembly.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    11. Depress and release the clutch pedal sub-assembly two or three times to ensure that the clutch pedal sub-assembly and the release lever operate smoothly. If the clutch pedal sub-assembly and the release lever do not operate smoothly, bleed the air from the clutch line.

    12. Measure the clutch pedal sub-assembly full stroke length again to ensure that it is within specifications. If it is not within specifications, repeat the adjustment procedures again from the beginning.

      Pedal stroke
      110 to 115 mm (4.331 to 4.528 in.)

  2. INSPECT CLUTCH PEDAL SUB-ASSEMBLY


    1. A004I9H

      Move the clutch pedal sub-assembly in the lateral direction with a force of approximately 10 N (1.0 kgf, 2.2 lbf) to check that the clutch pedal sub-assembly deflection is within the service limit.

      Maximum play
      4.0 mm (0.158 in.)

      If the play exceeds the maximum, replace the clutch pedal sub-assembly.