CLUTCH SWITCH

1990–95 Pick-Ups

2.4L ENGINES

1. Measure the clutch pedal height from the face of the pedal pad to the floorboard, and the clutch pedal clevis pin play (measured from the upper most pedal face position to the lowest pedal position without moving the clutch). The standard values are as follows:
   • Pedal height — 6.5–6.7 in. (166–171mm).
   • Clevis pin play — 0.8–1.4 in. (20–35mm).

     Fig. 1: When adjusting the clutch pedal, A is the pedal height and B is the clutch pedal clevis pin play

     Fig. 2: Use the stopper bolt or the clutch pedal switch to adjust the clutch pedal

2. If the clutch pedal height is not within the standard value range, turn pedal stopper bolt or clutch pedal position switch until the height is adjusted to the standard value.
3. If the clutch pedal free-play is not within the standard value range, adjust it by the following procedure:
   1. Pull the clutch cable lightly at the toeboard (firewall) and turn the adjusting nut until the adjusting nut-to-insulator clearance is adjusted to 0.12–0.16 in. (3–4mm).
   2. After making the adjustment, depress the clutch pedal several times and check that the clutch pedal play is within the standard value range.

      Fig. 3: Adjust the adjusting nut-to-insulator clearance to 0.12–0.16 in. (3–4mm) — cable-actuated clutches only

      Fig. 4: With the clutch depressed, measure distance C from the floor to the pedal pad

4. Measure the distance between the clutch pedal (the face of the pedal pad) and the floorboard when the clutch is disengaged. The standard value should be 2.4 in. (60mm) or more.
5. If the distance is less than the standard value, check the clutch itself.

3.0L ENGINES

1. Measure the clutch pedal height (A) from the face of the pedal pad to the floorboard, and the clutch pedal clevis pin play (B), which is measured at the face of the pedal pad. The standard values are as follows:
   • Pedal height — 6.5–6.7 in. (166–171mm).
   • Clevis pin play — 0.31–0.67 in. (8–17mm).
2. If either the clutch pedal height or the clutch pedal clevis pin play are not within the standard value range, adjust as follows:
   1. For vehicles without the cruise control system, turn the stopper bolt to adjust the clutch pedal height to agree with the standard value and then secure the bolt with the locknut.
   2. For vehicles with the cruise control system, unplug the clutch pedal position switch connector and turn the switch for standard clutch pedal height. Lock the switch in place with the locknut.
   3. Turn the pushrod to adjust the clutch pedal clevis pin play to agree with the standard value and then secure the pushrod with the locknut.

      Fig. 5: Turn the clutch master cylinder actuating rod to adjust the clutch pedal height, use the locking nut to hold it at the specified adjustment

      WARNING
      When adjusting the clutch pedal clevis pin play, be careful not to push the pushrod toward the master cylinder.

3. After completing the adjustments, confirm that the clutch pedal free-play (measured at the face of the pedal pad) and the distance between the clutch pedal (the face of the pedal pad) and the floorboard when the clutch is disengaged are within the standard value ranges.
   • Pedal free-play — 0.31–0.67 in. (8–17mm).
   • Clutch pedal distance — 2.4 in. (60mm) or more.
4. If the clutch pedal free-play (B) and the distance between the clutch pedal and the floorboard (C) when the clutch is disengaged do not agree with the standard values, it is probably the result of either air in the hydraulic system, or a faulty master cylinder or clutch. Bleed the air, or inspect the master cylinder or clutch.

1990–95 Monteros

1. Measure the clutch pedal height (A) from the face of the pedal pad to the floorboard, and the clutch pedal clevis pin play (B), which is measured at the face of the pedal pad. The standard values are as follows:
   • Pedal height — 7.30–7.50 in. (185.5–190.5mm).
   • Clevis pin play — 0.04–0.12 in. (1–3mm).
2. If either the clutch pedal height or the clutch pedal clevis pin play are not within the standard value range, adjust as follows:
   1. For vehicles without the cruise control system, turn the stopper bolt to adjust the clutch pedal height to agree with the standard value and then secure the bolt with the locknut.
   2. For vehicles with the cruise control system, unplug the clutch pedal position switch connector and turn the switch for standard clutch pedal height. Lock the switch in place with the locknut.
   3. Turn the pushrod to adjust the clutch pedal clevis pin play to agree with the standard value and then secure the pushrod with the locknut.

      WARNING
      When adjusting the clutch pedal clevis pin play, be careful not to push the pushrod toward the master cylinder.

3. After completing the adjustments, confirm that the clutch pedal free-play (measured at the face of the pedal pad) and the distance between the clutch pedal (the face of the pedal pad) and the floorboard when the clutch is disengaged are within the standard value ranges.
   • Pedal free-play (1992–95) — 0.24–0.51 in. (6–13mm).
   • Pedal free-play (1990–91) — 0.31–0.63 in. (8–16mm).
   • Clutch pedal distance — 1.4 in. (35mm) or more.

     Fig. 6: Measure the clutch pedal free-play C and the clutch's depressed height D

4. If the clutch pedal free-play (B) and the distance between the clutch pedal and the floorboard (C) when the clutch is disengaged do not agree with the standard values, it is probably the result of either air in the hydraulic system, or a faulty master cylinder or clutch. Bleed the air, or inspect the master cylinder or clutch.