Removal and installation of the clutch pedal

Clutch Pedal Components

Right Hand Drive Models

Note. It is possible to replace the axle bushings of the clutch pedal without dismantling the pedal assembly, despite the extremely limited access. Remove the cotter pins on both sides of the pedal axle and slide the thrust washers back, allowing the axle bushings to be pulled out of their seats and removed from the axle. Lubricate new bushings with universal grease such as Litol 24 or G00062 before installation (ask at auto chemical stores). With both bushings seated in their sockets, replace the thrust washers and secure the assembly with new cotter pins. In conclusion, do not forget to adjust the clutch drive cable (see Section Removal, installation and adjustment of the clutch cable).

Removing

1. Pedal assembly components are shown in the accompanying illustration.

2. In the engine compartment, disconnect the negative cable from the battery, then locate the transmission end of the clutch drive cable and fully loosen the adjusting nut, ensuring maximum slack in the cable.


3. Remove the center console (see Section Removal and installation of the center console).

4. Remove the radio receiver unit, then bend back the locking tabs and remove the radio frame from the receiving socket in the instrument panel. Disconnect the antenna cable and wiring, then remove the frame completely.


5. Release the latches and remove the sleeve connecting the heater casing to the rear footwell.



6. Disconnect the auxiliary spring from the clutch pedal. Under the instrument panel, remove the retainer securing the drive cable to the pedal. Release the tip of the cable from the pedal.



7. Disconnect the drive cable from the top of the accelerator pedal.




8. Disconnect the wiring harness from the brake light switch that is screwed into the top of the right pedal assembly bracket.

9. In the passenger footwell, remove the plastic retainer and remove the decorative panel from the left bracket of the pedal assembly.







10. Remove a clamp and release from a pedal a tip of fastening of draft of a pusher of a servo drive of the vacuum amplifier of brakes.


11. Give fixing nuts and remove an emphasis of a pedal of an accelerator and a foot emphasis from the left party of a pedal of coupling.







12. Release the clips and roll up the carpet on the bulkhead of the engine compartment, providing access to the lower nuts of the pedal bracket.




13. Give nuts of fastening of the left and right arms of pedal assembly. Remove the lower support plates from the engine compartment.

14. Carefully remove the pedal assembly from the vehicle.

15. With the assembly on the workbench, carefully unhook the brake pedal return spring from the rear of the servo arm. Remove the brake pedal axle retaining rings and remove the support brackets, axle bushings and return spring from the pedal assembly. Further disassembly is not possible. Clutch and brake pedals are supplied as a single assembly (on an individual basis, only axial bushings and cotter pins are subject to replacement - see the note at the beginning of the Section).

Installation

Installation is carried out in the reverse order. Pay special attention to the following points:

• a) Do not forget to lubricate the axle bushings of the pedal assembly with universal grease before installation (see note at the beginning of Section);
• b) Having connected the accelerator cable to the pedal, check the correctness of its adjustment;
• c) After connecting the clutch drive cable, adjust it in accordance with the instructions given in Section Removal, installation and adjustment of the clutch cable;
• d) Finally, connect the battery and check that the brake lights are working properly.

Left Hand Drive Models

Removing

1. In the engine compartment, disconnect the negative cable from the battery, then locate the transmission end of the clutch drive cable and fully loosen the adjusting nut, providing maximum slack in the cable.

2. Disconnect the auxiliary spring from the clutch pedal. Under the instrument panel, remove the fastening clip to the drive cable pedal. Release the tip of the cable from the pedal.

3. Remove the retainer from the end of the pedal shaft, slide the pedal out of its place and remove it from the support bracket complete with auxiliary spring.

4. Check the pedal for signs of wear and mechanical damage. Replace if necessary. The axial sleeve of the pedal also serves to seat the brake pedal. If the bushing needs to be replaced, care must be taken to securely lock the foot brake pedal while performing the procedure for removing the old bushing and installing a new one.

Installation

1. Install the auxiliary spring on the pedal, lubricate the pedal axle and bushing with multipurpose grease (see note at the beginning of Section).

2. Get the pedal to its regular place, following the correct installation of the auxiliary spring. Secure the assembly with a retainer.

3. Lubricate the end of the drive cable with multipurpose grease and connect it to the pedal, securing it with a retainer.

4. Connect the return spring to the pedal, then adjust the clutch cable (see Section Removal, installation and adjustment of the clutch cable). Finally, connect the negative wire to the battery.