See Figure 1
The clutch free-play is adjusted automatically by a built-in clutch control mechanism. This devise allows the clutch controls to self-adjust during normal operation.
The system consists of a spring-loaded gear quadrant, a spring-loaded pawl and a clutch cable which is spring-loaded to preload the release lever bearing. This compensates for movement of the release lever, as the clutch disc wears. The pawl, located at the top of the clutch pedal, engages the gear quadrant when the clutch pedal is depressed and pulls the cable through its continuously adjusted stroke. Clutch cable adjustments are not required because of this feature.
The self-adjusting feature should be checked every 5000 miles (8000 km). This is accomplished by insuring that the clutch pedal travels to the top of its upward position. Grasp the clutch pedal with your hand or put your foot under the clutch pedal, pull up on the pedal until it stops. Very little effort is required (about 10 lbs./4.5 Kg). Finally, depress the clutch pedal and listen for an audible "click.'' If you hear a sound, the clutch was in need of adjustment, and it has just adjusted itself.
REMOVAL & INSTALLATION
See Figure 2
- Disconnect the negative battery cable for safety.
- Remove the steering wheel, using puller T67L-3600-A or equivalent.
- Remove the lower dash panel section to the left of the steering column.
- Remove the shrouds from the steering column.
- Disconnect the brake lamp switch and the master cylinder pushrod from the brake pedal.
- Rotate the clutch quadrant forward and unhook the clutch cable from the quadrant. Allow the quadrant to slowly swing rearward.
- Remove the bolt holding the brake pedal support bracket lateral brace to the left side of the vehicle.
- Unplug all electrical connectors from the steering column.
- Remove the four nuts that hold the steering column to the brake pedal support bracket and lower the steering column to the floor.
- Remove the four booster nuts that hold the brake pedal support bracket to the dash panel.
- Remove the bolt holding the brake pedal support bracket to the underside of the instrument panel, then remove the brake pedal support bracket assembly from the vehicle.
- Remove the clutch pedal shaft nut and the clutch pedal as outlined.
- Slide the self-adjusting mechanism out of the brake pedal support bracket.
- Remove the self-adjusting mechanism shaft bushings from either side of the brake pedal support bracket and replace, if worn.
- Lubricate the self-adjusting mechanism shaft with motor oil and install the mechanism into the brake pedal support bracket.
- Position the quadrant towards the top of the vehicle. Align the flats on the shaft with the flats in the clutch pedal assembly; install the retaining nuts. Tighten them to 32-50 ft. lbs. (43-68 Nm).
- Position the brake pedal support bracket assembly beneath the instrument panel, aligning the holes with the studs in the dash panel. Loosely install the four nuts. Install the bolt through the support bracket into the instrument panel and tighten to 13-25 ft. lbs. (18-34 Nm).
- Tighten the four booster nuts that hold the brake pedal support bracket to the dash panel to 13-25 ft. lbs. (18-34 Nm).
- Connect the brake lamp switch and the master cylinder pushrod to the brake pedal.
- Attach the clutch cable to the quadrant.
- Position the steering column onto the four studs in the support bracket and start the four nuts, but do not tighten them.
- Engage the steering column electrical connectors.
- Install the steering column shrouds.
- Install the brake pedal support lateral brace.
- Now tighten the steering column attaching nuts to 20-37 ft. lbs. (27-50 Nm).
- Install the lower dash panel section.
- Install the steering wheel.
- Connect the negative battery cable.
- Check the steering column for proper operation.
- Depress and raise the clutch pedal several times to adjust the cable.
See Figure 2
- Remove the self-adjusting mechanism.
- Remove the two hairpin clips that hold the pawl and quadrant on the shaft assembly.
- Remove the quadrant and quadrant spring.
- Remove the pawl spring.
- Remove the pawl.
- Lubricate the pawl and quadrant pivot shafts with M1C75B or equivalent grease.
- Install the pawl. Position the teeth of the pawl toward the long shaft and the spring hole at the end of the arm. Do not position the spring hole beneath the arm.
- Insert the straight portion of the spring into the hole, with the coil up.
- Keeping the straight portion in the hole, rotate the spring 180 degrees to the left and slide the coiled portion of the spring over the boss.
- Hook the bent portion of the spring under the arm.
- Install the retainer clip on the opposite side of the spring.
- Place the quadrant spring on the shaft, with the bent portion of the spring in the hole in the arm.
- Place the lubricated quadrant on the shaft, aligning the projection at the bottom of the quadrant to a position beneath the arm of the shaft assembly. Push the pawl up so the bottom tooth of the pawl meshes with the bottom tooth of the quadrant.
- Install the quadrant retaining pin.
- Grasp the straight end of the quadrant spring with pliers and position it behind the ear of the quadrant.
- Install the self-adjusting mechanism.
- Install the clutch pedal assembly.