ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Clutch Pedal

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REMOVAL & INSTALLATION



Hydraulic Clutch Control System

See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the instrument panel lower cover, the driver knee bolster panel assembly and the vent duct.
  4.  
  5. Remove the retaining clip from the master cylinder-to-clutch pedal retaining pin, then slide the pin out of the right-hand side of the clutch pedal arm and master cylinder pushrod end. Separate the pushrod end from the clutch pedal arm.
  6.  
  7. Detach the clutch switch connector from the underdash wiring harness.
  8.  
  9. Remove the 4 pedal assembly-to-firewall mounting nuts, then remove the entire pedal assembly, which includes the clutch pedal, clutch pedal bracket, and clutch switch. Once the assembly is removed from the vehicle, the clutch pedal arm can be removed from the clutch pedal bracket by removing the retaining nut and bolt.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: To gain access to the clutch pedal, first remove the driver lower cover, the driver knee bolster panel and the vent duct-hydraulic clutch control assembly



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the clutch pedal assembly-hydraulic clutch control system

To install:
  1. If necessary, slide the pedal arm into the clutch pedal bracket and install the retaining bolt from the left-hand side of the bracket. Install the retaining bolt nut until snug.
  2.  
  3. Position the clutch pedal assembly onto the firewall and install the 4 mounting nuts. Tighten the 4 mounting nuts to 15 ft. lbs. (21 Nm).
  4.  
  5. Attach the clutch switch connector.
  6.  
  7. Position the master cylinder pushrod end over the clutch pedal arm, slide the jaw joint pin through both the pushrod and the pedal arm from the right-hand side of the assembly. Install a retaining clip on the left-hand end of the pin.
  8.  
  9. Adjust the clutch pedal height and free-play and the clutch switch clearance, as described earlier in this section.
  10.  
  11. Install the vent duct, the driver knee bolster panel assembly and the instrument panel lower cover.
  12.  
  13. Connect the negative battery cable.
  14.  

Cable Clutch Control System

See Figure 3

  1. Disconnect the negative battery cable.
  2.  
  3. If necessary, remove the instrument panel lower cover, the driver knee bolster panel assembly and the vent duct.
  4.  
  5. Disconnect the clutch pedal return spring from the clutch pedal arm and bracket.
  6.  
  7. Remove the clutch pedal pivot bolt nut, then pull the pivot bolt out of the clutch pedal bracket.
  8.  
  9. Unhook the clutch cable from the upper end of the clutch pedal arm.
  10.  
  11. Remove the clutch pedal arm from the vehicle.
  12.  
  13. Detach the clutch switch connector from the underdash wiring harness.
  14.  
  15. Remove the 4 pedal bracket-to-firewall mounting nuts, then remove the pedal bracket assembly, which includes the clutch pedal bracket and clutch switch or adjusting bolt.
  16.  



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the clutch pedal assembly on cable-actuated clutch systems

To install:
  1. Position the clutch pedal bracket assembly onto the firewall and install the 4 mounting nuts. Tighten the 4 mounting nuts to 15 ft. lbs. (21 Nm).
  2.  
  3. Attach the clutch switch wiring harness connector.
  4.  
  5. Position the clutch cable end over the upper end of the clutch pedal arm, slide the clutch pedal up into the bracket and install the pivot bolt and nut. Make sure to position the bushings and washers correctly when inserting the clutch pedal. Tighten the clutch pedal pivot bolt nut to 15 ft. lbs. (21 Nm).
  6.  
  7. Adjust the clutch pedal height and free-play and the clutch switch clearance (if equipped), as described earlier in this section.
  8.  
  9. If necessary, install the vent duct, the driver knee bolster panel assembly and the instrument panel lower cover.
  10.  
  11. Connect the negative battery cable.
  12.  

 
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