Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Clutch Pedal

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REMOVAL & INSTALLATION



Except Legacy

See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the clutch and brake pedal assembly-Loyale shown

  1. Disconnect the negative battery cable.
  2.  
  3. Disengage the accelerator cable from the throttle body.
  4.  
  5. Disengage and detach the clutch cable from the following parts.
    1. Clutch release fork
    2.  
    3. Clamp on the transaxle case.
    4.  
    5. Grommet of the toe board.
    6.  

  6.  
  7. Detach the rim panel and lower the steering column.
  8.  
  9. Disengage the following parts from the pedal bracket.
    1. Operating rod of the brake booster.
    2.  
    3. Electrical connectors for the clutch, cruise control and stop light switches.
    4.  
    5. Accelerator cable.
    6.  

  10.  

Take care not to kink the accelerator cable.

  1. Remove the pedal bracket assembly along with the clutch cable while supporting the brake booster in the engine compartment.
  2.  
  3. Detach the following parts from the pedal bracket assembly.
    1. Accelerator pedal return spring.
    2.  
    3. Accelerator pedal.
    4.  
    5. Clutch cable.
    6.  
    7. Brake pedal return spring.
    8.  
    9. Clutch pedal return spring, if equipped with hill holder.
    10.  
    11. Circlip retaining pedal shaft
    12.  
    13. Clutch pedal and brake pedal
    14.  
    15. Stop light switch
    16.  

  4.  

To install:
  1. Attach the switches on to the pedal bracket temporarily.
  2.  
  3. Clean inside of the bores of the clutch pedal and brake pedal, apply grease and set the bushing into the bores.
  4.  
  5. Align bores of the pedal bracket, clutch pedal and brake pedal.
  6.  
  7. Attach the brake pedal return spring and clutch pedal return spring (vehicle with a hill holder), then install the pedal shaft completely to prevent it from rotating.
  8.  

Be sure to clean up the bushings and apply grease prior to installing the shaft.

  1. Clean and apply grease to the shaft and inside of the bore of the accelerator pedal. Install the accelerator pedal onto the pedal bracket.
  2.  
  3. Set brake pedal position by adjusting position of the stop light switch.
  4.  
  5. Connect the clutch cable to the clutch pedal by using clevis pin and clip.
  6.  
  7. Insert the clutch cable into the hole on the toe board and set the pedal bracket above the steering column.
  8.  

Be careful not to bend the clutch cable to much.

  1. Insert bolts of the brake booster into the holes on the toe board, support it form the engine compartment and align the holes of the pedal bracket with the bolts. The operating rod of the brake booster should be engaged with the brake pedal.
  2.  
  3. While pushing the pedal bracket upward firmly, tighten the 4 nuts and 2 bolts at its upper surface.
  4.  
  5. Pull out the accelerator inner cable to its maximum stroke and attach it to the accelerator pedal. Pull the accelerator cable from the throttle body side.
  6.  

Take care not to kink the accelerator cable.

  1. Engage the electrical connectors for the clutch, cruise control and stop light switches.
  2.  
  3. Install the steering column.
  4.  
  5. Engage the accelerator cable to the throttle body.
  6.  
  7. Check the operation of the accelerator cable by operating the accelerator pedal by hand.
  8.  
  9. Attach the clutch cable grommet to the toe board, then engage the clutch cable to the clutch release fork.
  10.  
  11. Cover the outer cable end with the protective boot. Connect the negative battery cable.
  12.  

Legacy

See Figure 2

Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the clutch and brake pedal assembly-Legacy non-turbocharged

  1. Disengage the clutch cable from the release lever. (non-turbo vehicles).
  2.  
  3. On vehicles equipped with a turbocharger, remove the steering bolts.
    1. Raise and support the vehicle safely and remove the 2 steering bolts.
    2.  
    3. Lower the vehicle to the floor.
    4.  

  4.  
  5. Remove the instrument panel lower cover from the pedal bracket.
    1. Disengage the operating rod at the brake booster.
    2.  
    3. Disengage the electrical connectors for the clutch, cruise control and stop light switches.
    4.  

  6.  
  7. Remove the clevis pin which secures the pedal to the pushrod, (turbo vehicles).
  8.  
  9. Remove the nut which secures the clutch master cylinder (turbo vehicles).
  10.  
  11. Remove the steering assembly (turbo vehicles).
  12.  
  13. Remove the bolts and nuts which secure the brake and clutch pedals.
  14.  
  15. Remove the pedal assembly and the clutch cable as unit.
  16.  

Prior to removing the clutch cable from the toe board, remove the grommet. Slowly remove the clutch cable, being careful not to scratch it.

  1. Insert the clutch cable into the hole on the toe board and set the pedal bracket above the steering column.
  2.  

Be careful not to bend the clutch cable to much.

  1. Insert the bolts of the brake booster into holes on the toe board supporting the booster from the engine compartment.
  2.  
  3. Align the holes of the pedal bracket onto the bolts.
  4.  
  5. Engage the operating rod of the brake booster to the brake pedal using the clevis pin and snap pin.
  6.  
  7. Engage the electrical connectors for the clutch, cruise control and stop light switches
  8.  
  9. On vehicles equipped with turbocharger, install the steering assembly and bolts.
  10.  
  11. Attach the clutch cable grommet to the toe board and then connect the clutch cable to the clutch release fork.
  12.  
  13. Cover the outer cable end with the protective boot.
  14.  

 
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