ION 2006-2007

Adjustments

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The hydraulic clutch system is self-adjusting.

Pedal Height/Travel Diagnosis



The hydraulic clutch system is self-adjusting; therefore, no manual clutch pedal adjustments are necessary or possible. However, because the pedal travel is directly related to the clutch fork travel, the operating condition of the hydraulic system may be checked using clutch pedal travel.

  1. Use a straightedge horizontally positioned from the center of the clutch pedal to the driver's seat, then depress the clutch pedal and measure pedal travel. The clutch pedal travel should be 5.3-6.2 in. (135-156mm). If the pedal travel is insufficient, look for an obvious cause, such as carpet or a floor mat blocking the pedal or a faulty/damaged pedal.
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  3. Through the access hole on the side of the transaxle (immediately to the right of the slave cylinder), use a caliper or depth gauge to measure travel of the clutch fork with the pedal in the full up and full down positions. Subtract the full down measurement from the full up figure to determine fork travel.
    NOTE
    If no caliper or depth gauge is available, use a round wire rod in the access hole and mark the pedal up/down positions. Then measure the distance between the 2 marks to determine fork travel.

  4.  
  5. Compare the fork and pedal travel measurements using the chart.
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  7. If fork travel is less than the minimum allowable, check the following. (Conditions a, b and e require replacement of the master/slave cylinder assembly:
    1. Fluid leaks in the hydraulic system.
    2.  
    3. Air in the system.
    4.  
    5. Improper installation of the master/slave cylinder.
    6.  
    7. Damaged master or slave cylinder.
    8.  
    9. Damage to the front of the dashboard.
    10.  

  8.  
  9. If fork travel is acceptable and the hydraulics are working properly, check for a bent fork or damaged pressure plate, which may cause the improper pedal travel.

    Click image to see an enlarged view

    Fig. Use a straightedge to measure pedal travel



    Click image to see an enlarged view

    Fig. An access hole is provided in the transaxle housing, in order to measure fork travel



    Click image to see an enlarged view

    Fig. Compare fork and pedal travel using the chart

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