The manual transaxle clutch release system has a unique self-adjusting mechanism to compensate for clutch disc wear. This adjuster mechanism is located with the clutch cable assembly. The preload spring maintains tension on the cable. This tension keeps the clutch release bearing continuously loaded against the fingers of the clutch cover assembly.
When servicing this vehicle or if removing and installing the clutch cable, do not pull on the clutch cable housing to remove it from the dash panel. Damage to the cable self-adjuster may occur.
To check the function of the adjuster mechanism, use the following procedure:
- With slight pressure, pull the clutch release lever end of the cable to draw the cable taut.
- Push the clutch cable housing toward the dash panel. With less than 25 lbs. (11 kg) of effort, the cable housing should move 1.2-2.0 inch (30-50mm). This indicates proper adjuster mechanism function.
- If the cable does not adjust, determine if the mechanism is properly seated on the bracket.
Pedal Height & Free-Play
- Measure the clutch pedal height from the face of the pedal pad to the floorboard. Compare the measured value with the desired distance of 7.0-7.09 in. (175-180mm) for 1999 vehicles, or 6.88-7.00 in. (174.7-177.7mm) for 2001-05 vehicles.
- Measure the clutch pedal clevis pin play at the face of the pedal pad. Press the pedal lightly until resistance is met, and measure this distance. The clutch pedal clevis pin play should be within 0.040-0.120 in. (1-3mm).
If the clutch pedal height or clevis pin play, is not within the standard values, adjust as follows:
- If not equipped with cruise control, turn and adjust the stop bolt so the pedal height is the standard value, then tighten the locknut.
- If equipped with cruise control system, disconnect the clutch switch connector and turn the switch to obtain the standard clutch pedal height. Then, lock by tightening the locknut.
Turn the pushrod to adjust the clutch pedal clevis pin play to agree with the standard value and secure the pushrod with the locknut.
NOTEWhen adjusting the clutch pedal height or the clutch pedal clevis pin play, be careful not to push the pushrod toward the master cylinder.
- Check that when the clutch pedal is depressed all the way, the interlock switch switches over from ON to OFF .
- Move the clutch pedal until the resistance begins to increase; measure between this point and the pedal resting point to determine the clutch pedal free-play. The clutch pedal free-play measurement should be between 0.240-0.510 in. (6-13mm). With the pedal fully disengaged, check the distance between the bulkhead and the top of the pedal pad. The measurement should be 2.760 in. (70mm) or more for 199 vehicles. For 2001-05 vehicles, the measurement should be 3.8 in. (95.4mm) for 2.4L engines or 3.5 in. (89.5mm) for 3.0L engines.
- If the measurements are not within specification, bleed the clutch hydraulic system. If after bleeding the measurements are still not within specified range, there is a faulty component in the system, which must be replaced.