Here are some basic instructions for the pedal and cable freeplay adjustments. Alot of the adjustments you will need can be done by adjusting the cable/cable freeplay. Becareful not to go too extreme in your adjustments because you can damage the clutch assembly.
*CLUTCH PEDAL HEIGHT
-Disconnect clutch cable at release lever so that cable will not interfere with measurement.
-Move carpeting and insulation away from pedal area.
Clutch Pedal Adjustments
-Measure distance from upper center of pedal to dash panel. Measurement should be 8.2-8.4 inch. If distance is not as specified, proceed to next step.
-Inspect clutch pedal mounting for damaged, worn or missing parts. Replace parts as necessary. If pedal mounting is satisfactory, proceed to next step.
-Remove instrument panel bracket and air duct located underneath steering column.
-Loosen clutch switch locknut, then turn switch in or out as required until pedal height is as specified in step 3.
-Reconnect clutch cable to release lever, then adjust pedal freeplay as outlined below.
-Recheck pedal height measurement. If height adjustment is not within specification, check clutch cable for binding or damage.
-Reinstall air duct and instrument panel bracket.
*PEDAL FREEPLAY (cable adjustment under the hood atached to the throwout bearing fork)
-Move clutch pedal back and forth and measure freeplay.
-Pedal freeplay should be 0.350-0.590 inch. If freeplay is not as specified, proceed to next step.
-Checking Clearance Between Release Lever & Cable Pin
-Pull back on release lever, then measure clearance between lever and cable pin. Clearance should be 0.060-0.100 inch.
-If clearance is not as specified, thread adjuster in or out until specified clearance is obtained.
-Recheck freeplay. If freeplay is still not within specified limits, inspect clutch release components for damage.
Tuesday, November 17th, 2009 AT 12:49 PM