How to remove clutch pedal - 2004 Mazda 3

CLUTCH PEDAL REPLACEMENT (CLUTCH) Document ID# 46043 Clutch Pedal Replacement

Removal Procedure

1. Remove the master cylinder rod from the clutch pedal.



2. Remove the clutch pedal from the support by depressing the side tabs.

Installation Procedure

1. Position the clutch pedal into the support.



2. Secure the master cylinder rod to the clutch pedal.

Good Luck

Check the spring to see if it has snapped anywhere within it's coil.

Remove the cable and check operation of the pedal and spring mechanism.
If all is well, then with a lever, check that the clutch release arm on the gearbox is operational. If that is also sticking, then you will have to remove the gearbox to investigate further.
If not sticking, then also remove the clutch cable outer sleeve, and replace.

Remove the clutch linkage from pedal (older models) then of the left side of the brake and clutch pedal remove the nut from the shaft and remove the pedal. Newer models with a clutch cable only require removing the nut because the cable is to the right of the brake pedal.

clutch is supposed to be self adjusting. Here are instructions for replacing the adjuster:

REMOVAL & INSTALLATION


See Figure 1

1. Disconnect the battery cable from the negative terminal of the battery.
2. Remove the steering wheel using a steering wheel puller, Tool T67L-3600-A or equivalent.
3. Remove the lower dash panel section to the left of the steering column.
4. Remove the shrouds from the steering column.
5. Disconnect the brake lamp switch and the master cylinder pushrod from the brake pedal.
6. Rotate the clutch quadrant forward and unhook the clutch cable from the quadrant. Allow the quadrant to slowly swing rearward.
7. Remove the bolt holding the brake pedal support bracket lateral brace to the left side of the vehicle.
8. Disconnect all electrical connectors from the steering column.
9. Remove the 4 nuts that hold the steering column to the brake pedal support bracket and lower the steering column to the floor.
10. Remove the 4 booster nuts that hold the brake pedal support bracket to the dash panel.
11. Remove the bolt that holds the brake pedal support bracket to the underside of the instrument panel, and remove the brake pedal support bracket assembly from the vehicle.
12. Remove the clutch pedal shaft nut and the clutch pedal, as outlined above.
13. Slide the self-adjusting mechanism out of the brake pedal support bracket.
14. Examine the self-adjusting mechanism shaft bushings on either side of the brake pedal support bracket, and replace if worn.

To install:

1. Lubricate the self-adjusting mechanism shaft with motor oil and install the mechanism into the brake pedal support bracket.
2. Position the quadrant towards the top of the vehicle. Align the flats on the shaft with the flats in the clutch pedal assembly, and install the retaining nuts. Tighten to 32-50 ft. lbs. (43-67 Nm).
3. Position the brake pedal support bracket assembly beneath the instrument panel, aligning the four holes with the studs in the dash panel. Install the four nuts loosely.
4. Install the bolt through the support bracket and into the instrument panel. Tighten to 13-25 ft. lbs. (18-34 Nm).
5. Tighten the four booster nuts that hold the brake pedal support bracket to the dash panel to 13-25 ft. lbs. (18-34 Nm).
6. Connect the brake lamp switch and the master cylinder pushrod to the brake pedal.
7. Attach the clutch cable to the quadrant.
8. Position the steering column onto the four studs in the support bracket and start the four nuts.
9. Connect the steering column electrical connectors.
10. Install the steering column shrouds.
11. Install the brake pedal support lateral brace.
12. Tighten the steering column attaching nuts to 20-37 ft. lbs. (27-50 Nm).
13. Install the lower dash panel section.
14. Install the steering wheel.
15. Connect the battery cable to the negative terminal on the battery.
16. Check the steering column for proper operation.
17. Depress the clutch pedal several times to adjust the cable.

Remove the fluid line, then go inside cab at clutch pedal remove linkage that connects master and clutch pedal. Remove bolts that hold it in place and remove unit. reinstall in reverse order and bleed system at clutch slave by opening bleeder then pushing clutch pedal down and holding until bleeder is closed. repeat until solid fluid comes out, then with bleeder closed pump clutch pedal three times and open bleeder to relieve any left over air.

Clutch Pedal Position (CPP) Switch
The clutch pedal position switch (CPP) is controlled by the clutch pedal. Depressing the clutch pedal manually closes the CPP switch and allows engine cranking. The CPP switch will also deactivate the speed control system.
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303-14A: Electronic Engine Controls — Gasoline Engines 1999 F-Super Duty 250-550 Workshop Manual
REMOVAL AND INSTALLATION Clutch Pedal Position (CPP) Switch Removal

1. CAUTION: Always disconnect the battery ground cable prior to working on the electronic engine controls.
   Disconnect the battery ground cable; refer to Section 414-01 .

1. Disconnect electrical connector from clutch pedal position switch (CPP) (9A837).

1. Release the clutch pedal position switch (CPP) (11A152) from the orientation clip.

1. Remove the plastic retainer.
   1. Push the lock tabs together.
   1. Slide the plastic retainer off the clutch pedal position switch.

1. Remove the clutch pedal position switch.

Installation

1. Follow the removal procedure in reverse order.

1-disconnect battery. 2- remove all lower dash plastic panels. 3- disconnect all plugs on steering coloumn. 4- remove shear bolts on steering coloumn, easy with a long 8" sharp chisel (get 2 x new shear bolts £0.50p each). 5-loosen & remove bolt at steering rack in drivers footwell, mark position of spline before removing this makes it east to refit (tipex). 6- pull steering coloumn out towards you & it will slide off the bush quite easy. 7- loosen clutch cable adjustment & remove cable nipple at pedal. 8-remove clutch pedal. 9- pull brake pedal out of plastic insert, this will break there is no way to remove this without breaking the plastic clip. get a new brake pedal clip insert for a Mk 3 golf £4 its the same (dont let VW sell you a new pedal) 10- remove 5 x nuts holding pedal box to bulkhead/brake servo. 11- cut 2 x cable ties holding throttle wiring & disconnetc plug above heater on drivers side. 12- push/pull brake servo slightly out of bulk head. 13- remove pedal box.
Cause of the problem- The clutch bracket is only held to the pedal box with 2 x spot welds & a 10mm tack on the top corner.
Repair- Fully Weld the clutch bracket to the pedal box. Great repair.
refitting reverse of above.
Duration around 6/8 hours Less if you get the spare parts before you start.
I wasted time trying to remove the brake pedal without breaking the clip impossible to do even with theVW tool. £4 on a new clip is well worth it.

the self adjust mechanism is made up of two pieces a pawl and ratchet. removing them is more awkward than difficult. you need to remove the clutch pedal by knocking out the pivot shaft that also supports the brake pedal just knock it out far enough to remove the clutch pedal after removing the clip. when the pedal is out you will see how it is assembled. the hardest part of the job is replacing the spring which is attached to the pedal this must be hooked back into the pedal last i find a strong piece of wire threaded through the hole in the pedal does the trick this is a job for someone who has some experience good luck

REMOVAL:

1. Lift clutch pedal to uppermost position to disengage clutch and brake pedal pivot shaft.
2. Push clutch and brake pedal pivot shaft forward and unhook clutch release lever cable from clutch and brake pedal pivot shaft and allow it to slowly swing rearward.
3. Raise and support vehicle.
4. Remove clutch release lever dust shield.
5. Disconnect clutch release lever cable from clutch release shaft.
6. Remove retaining clip, then clutch release lever cable from flywheel housing.
7. Remove starter motor from flywheel housing, then engine rear plate to front lower flywheel housing bolts.
8. Remove transmission.
9. Remove flywheel housing back just far enough to clear clutch pressure plate, then remove housing.
10. Remove clutch release shaft from flywheel housing by pulling it through window in flywheel housing until retainer spring disengages from pivot.
11. Remove clutch release hub and bearing from clutch release shaft.
12. Loosen six clutch pressure plate bolts evenly to release spring tension gradually and avoid distorting clutch pressure plate. If same clutch pressure plate is to be installed, mark plate and flywheel so pressure plate can be installed in its original position.
13. Remove clutch pressure plate and clutch disc from flywheel.

INSTALLATION:

1. Position clutch disc and pressure plate assembly on flywheel, noting following:
   1. Three flywheel housing to block dowels on flywheel must be properly aligned with clutch pressure plate.
   2. Bent, damaged or missing flywheel housing to block dowels must be replaced.
   3. tart clutch pressure plate bolts but do not tighten.
   4. Avoid touching clutch disc face, dropping parts or contaminating parts with oil or grease.
   5. Align clutch disc using suitable alignment tool inserted in pilot bearing.
   6. To avoid clutch pressure plate distortion, alternately tighten bolts a few turns at a time, until they are all tight, then tighten to specifications.
   
   
2. Install transmission to flywheel housing.
3. Install engine rear plate to flywheel front lower housing bolts, then connect clutch release cable to flywheel housing and connect retaining clip.
4. Connect clutch release lever cable to clutch release shaft, then install clutch release lever dust shield.
5. Install starter motor.
6. Lower vehicle, then install clutch release lever cable as follows:
   1. Lift clutch pedal to disengage clutch and brake pedal pivot shaft.
   2. Push clutch and brake pedal pivot shaft forward and hook end of clutch release lever cable over rear of clutch and brake pedal pivot shaft.
   
   
7. Cycle clutch pedal several times to adjust clutch release lever cable

To replace the clutch master, you must remove the under hood fuse box and air filter housing assm, then remove the hydraulic line that goes into the inlet port of the clutch master, then inside the car, remove the hush panel/knee bolster panel from under the steering column, and loosen the boilts that retain the brake pedal to the firewall, then remove the two 10mm bolts that secure the clutch master to the brake pedal assm. Reverse procedure ti install, then fill the brake master cylinder with clean fluid, loosen the bleeder screw at the top of the trans, and bleed the clutch as you would the regular brake system, but never pump the pedal, tighten screw, with foot off of clutch pedal open screw and press pedal to floor, then tighten screw before you release pedal, then release pedal loosen screw, etc. until no more air comes out, it may take quite a few times to fully bleed the system.