Previous Next

Clutch Pedal

REMOVAL & INSTALLATION

Pick-Up
CABLE ACTUATED CLUTCH
  1. Pull the cable out and turn the adjusting nut counter-clockwise to increase the cable play.
  2. Disconnect the cable from the clutch lever.
  3. Unscrew the nut on the right-hand end of the clutch pedal pivot bolt. Remove also the lockwasher and the flat washer.
  4. Pull the clutch lever off the end of the pivot bolt. Make sure to note the position of the lever before removal.
  5. Slide the clutch pedal out to the left. The pivot bolt will come out with the pedal. Make sure to save the pedal-side clutch pedal bushing.

    Fig. 1: Clutch pedal removal and installation — cable-actuated clutches on earlier Monteros and Pick-ups

  6. To install, slide the clutch pedal bushing onto the pivot bolt, then slide the pivot bolt through the pedal support member.
  7. Insert the right-hand side clutch pedal bushing into the pivot bolt tube, then slide one of the flat washers onto the pivot bolt.
  8. Hook the clutch lever into the end of the clutch cable, then slide onto the clutch pedal pivot bolt.
  9. Install the flat washer, the lockwasher and the end nut onto the pivot bolt. Tighten until snug.
  10. Adjust the clutch and brake pedals — refer to the previous procedures in this section.
HYDRAULIC CLUTCH
  1. Loosen and remove the bracket retaining bolt, then remove the bracket itself.
  2. Remove the turnover spring from the clutch pedal.
  3. Unscrew the stopper bolt (on vehicles without auto-cruise control system) or the clutch switch (vehicles with the auto-cruise control system). The stopper bolt/ clutch switch is located just above the small bracket on the pedal assembly main bracket.
  4. Remove the cotter pin, which is holding the clutch master cylinder rod to the clutch pedal. A new cotter pin will be needed upon installation.
  5. Pull the clevis pin out of the clutch pedal, thereby disconnecting the clutch master cylinder from the pedal.
  6. Remove the clutch pedal mounting bolt, then pull the clutch pedal down and out of the pedal assembly main bracket. Make sure to retain the two bushings and the spacer.

    Fig. 2: Clutch pedal removal and installation — 1990–95 Pick-ups equipped with 3.0L engines

  7. For installation, insert the two bushings and the spacer onto the clutch pedal.
  8. Insert the clutch pedal up into the pedal assembly main bracket, then slide the clutch pedal mounting bolt through the main bracket from the right-hand side.
  9. Install the lockwasher and mounting bolt nut to the clutch pedal mounting bolt. Tighten the nut to 18–25 ft. lbs. (25–35 Nm).
  10. Slide the clevis pin through the clutch pedal from the right-hand side. Hook the clutch master cylinder rod onto the clevis pin. Make sure to install the flat washer on the clevis pin after the clutch master cylinder has been installed.
  11. Insert the new cotter pin through the clevis pin end-hole, then bend each "arm'' of the cotter pin in opposite directions.
  12. Install the stopper bolt or clutch switch to the pedal assembly main bracket.
  13. Install the turnover spring to the clutch pedal and the small bracket. Mount the small bracket to the main bracket with the retaining bolt.
  14. Adjust the clutch pedal — refer to the previously described procedures in this section.
Montero
CABLE ACTUATED CLUTCH
  1. Pull the cable out and turn the adjusting nut counter-clockwise to increase the cable play.
  2. Disconnect the cable from the clutch lever.
  3. Unscrew the nut on the right-hand end of the clutch pedal pivot bolt. Remove also the lockwasher and the flat washer.
  4. Pull the clutch lever off the end of the pivot bolt. Make sure to note the position of the lever before removal.
  5. Slide the clutch pedal out to the left. The pivot bolt will come out with the pedal. Make sure to save the pedal-side clutch pedal bushing.
  6. To install, slide the clutch pedal bushing onto the pivot bolt, then slide the pivot bolt through the pedal support member.
  7. Insert the right-hand side clutch pedal bushing into the pivot bolt tube, then slide one of the flat washers onto the pivot bolt.
  8. Hook the clutch lever into the end of the clutch cable, then slide onto the clutch pedal pivot bolt.
  9. Install the flat washer, the lockwasher and the end nut onto the pivot bolt. Tighten until snug.
  10. Adjust the clutch and brake pedals — refer to the previous procedures in this section.
HYDRAULIC CLUTCH — 1989–90 2.6L ENGINES
  1. Remove the spring from the clutch pedal.
  2. Remove the cotter pin and washer, which is holding the clutch master cylinder rod to the clutch pedal. A new cotter pin will be needed upon installation.
  3. Pull the clevis pin out of the clutch pedal, thereby disconnecting the clutch master cylinder from the pedal.
  4. Remove the clutch pedal bracket.
  5. Remove the clutch pedal mounting bolt, then pull the clutch pedal down and out of the pedal assembly main bracket. Make sure to retain the two bushings and the spacer.
  6. For installation, insert the two bushings and the spacer onto the clutch pedal.
  7. Apply a thin coating of grease to the pedal mounting bolt. Insert the clutch pedal up into the pedal assembly main bracket, then slide the clutch pedal mounting bolt through the main bracket from the right-hand side.
  8. Install the lockwasher and mounting bolt nut to the clutch pedal mounting bolt. Tighten the nut to 18–25 ft. lbs. (25–35 Nm).

    Fig. 3: Clutch pedal removal and installation — 1989–90 Monteros equipped with 2.6L engines (earlier years with hydraulic clutches are similar)

  9. Install the clutch pedal bracket.
  10. Apply a small coating of grease to the clevis pin. Slide the clevis pin through the clutch pedal from the right-hand side. Hook the clutch master cylinder rod onto the clevis pin. Make sure to install the flat washer on the clevis pin after the clutch master cylinder has been installed.
  11. Insert the new cotter pin through the clevis pin end-hole, then bend each "arm'' of the cotter pin in opposite directions.
  12. Install the stopper bolt to the clutch pedal bracket, if removed.
  13. Install the spring to the clutch pedal.
  14. Adjust the clutch pedal — refer to the previously described procedures in this section.
HYDRAULIC CLUTCH — 1990–91 3.0L ENGINES
  1. Remove the return spring from the clutch pedal and the small bracket.
  2. Remove the small bracket by removing the mounting bolts. If needed, the small bushings and cotter pins can be removed from the small bracket and clutch pedal, however this is not necessary for removal of the pedal. If the cotter pins are removed, new will be needed for assembly.
  3. Unscrew the stopper bolt (on vehicles without auto-cruise control system) or the clutch switch (vehicles with the auto-cruise control system). The stopper bolt/ clutch switch is located just above the small bracket on the pedal assembly main bracket.
  4. Remove the cotter pin and washer, which is holding the clutch master cylinder rod to the clutch pedal. A new cotter pin will be needed upon installation.
  5. Pull the clevis pin out of the clutch pedal, thereby disconnecting the clutch master cylinder from the pedal.
  6. Remove the clutch pedal bracket.
  7. Remove the clutch pedal mounting bolt, then pull the clutch pedal down and out of the pedal assembly main bracket. Make sure to retain the two bushings and the spacer.

    Fig. 4: Clutch pedal removal and installation — 1990–91 Monteros equipped with 3.0L engines

  8. For installation, insert the two bushings and the spacer onto the clutch pedal.
  9. Apply a thin coating of grease to the pedal mounting bolt. Insert the clutch pedal up into the pedal assembly main bracket, then slide the clutch pedal mounting bolt through the main bracket from the right-hand side.
  10. Install the lockwasher and mounting bolt nut to the clutch pedal mounting bolt. Tighten the nut to 18–25 ft. lbs. (25–35 Nm).
  11. Install the clutch pedal bracket.
  12. Apply a small coating of grease to the clevis pin. Slide the clevis pin through the clutch pedal from the right-hand side. Hook the clutch master cylinder rod onto the clevis pin. Make sure to install the flat washer on the clevis pin after the clutch master cylinder has been installed.
  13. Insert the new cotter pin through the clevis pin end-hole, then bend each "arm'' of the cotter pin in opposite directions.
  14. Install the stopper bolt or clutch switch to the clutch pedal bracket.
  15. Mount the small bracket to the main bracket with the retaining bolts until snug.
  16. Install the spring to the clutch pedal. Install the bushings and cotter pins if they were removed upon disassembly.
  17. Adjust the clutch pedal — refer to the previously described procedures in this section.
HYDRAULIC CLUTCH — 1992–95
  1. Remove the cotter pin and washer, which is holding the clutch master cylinder rod to the clutch pedal. A new cotter pin will be needed upon installation.
  2. Pull the clevis pin out of the clutch pedal, thereby disconnecting the clutch master cylinder from the pedal.
  3. Unplug the interlock switch harness connector.
  4. Disconnect the clutch master cylinder from the clutch pedal assembly by removing the retaining nuts (one is inside the vehicle in the clutch pedal bracket, the other one is in the engine compartment near the clutch master cylinder).
  5. Remove the entire clutch pedal assembly from the firewall. Once the entire unit has been removed, further disassembly can be done.
  6. Remove the upper turnover spring retaining clevis pin (a new cotter pin will be needed). Disassemble the turnover spring assembly, which consists of rod A, the spring, rod B and rod B's bushing. Remove the lower retaining clevis pin from the clutch pedal.
  7. Unscrew the stopper bolt (on vehicles without auto-cruise control system) or the clutch switch (vehicles with the auto-cruise control system). The stopper bolt/ clutch switch is located on the pedal assembly main bracket.
  8. Remove the clutch pedal mounting bolt, then pull the clutch pedal down and out of the pedal assembly main bracket. Make sure to retain the two bushings and the spacer.

    Fig. 5: Clutch pedal removal and installation — 1992–95 Monteros

  9. For installation, insert the two bushings and the spacer onto the clutch pedal.
  10. Apply a thin coating of grease to the pedal mounting bolt. Insert the clutch pedal up into the pedal assembly main bracket, then slide the clutch pedal mounting bolt through the main bracket from the right-hand side.
  11. Install the lockwasher and mounting bolt nut to the clutch pedal mounting bolt. Tighten the nut to 18–25 ft. lbs. (25–35 Nm).
  12. Install the stopper bolt or the clutch switch.
  13. Assemble the turnover spring (rod A-turnover spring-rod B) and install the lower end onto the clutch pedal with the bushing (oiled), the flat washer and a new cotter pin.
  14. Install the upper end of the turnover spring assembly into the main bracket, using the clevis pin, the flat washer and a new cotter pin. Apply a thin film of grease to the clevis pin.
  15. Install the clutch pedal assembly onto the firewall and tighten the two mounting bolts (one inside, one outside) to 9 ft. lbs. (13 Nm).
  16. Apply a small coating of grease to the clevis pin. Slide the clevis pin through the clutch pedal from the right-hand side. Hook the clutch master cylinder rod onto the clevis pin. Make sure to install the flat washer on the clevis pin after the clutch master cylinder has been installed.
  17. Insert the new cotter pin through the clevis pin end-hole, then bend each "arm'' of the cotter pin in opposite directions.
  18. Adjust the clutch pedal — refer to the previously described procedures in this section.

Previous Next