Clutch Interlock/Upstop Switch-LHD

CLUTCH INTERLOCK/UPSTOP SWITCH

REMOVAL
LHD
1. Disconnect and isolate battery negative cable.





2. Remove left lower instrument panel bezel (2).
3. Disconnect interlock switch and brake lamp switch connectors.
4. Disconnect clutch master cylinder rod from clutch pedal pin. Inspect plastic retainer upon removal. If retainer is damaged, it MUST be replaced.





5. Remove brake booster push rod retaining clip (1) from brake pedal. Disengage rod from pedal.
6. Remove two pedal assembly bracket to instrument panel nuts.
7. Remove four brake booster/pedal bracket-to-dash panel nuts.
8. From under the hood, pull brake master cylinder/ booster far enough forward to obtain pedal to bracket stud clearance.





9. Remove the pedal bracket assembly (1).





10. Remove pedal pivot shaft and remove brake and clutch pedals (3).
11. Remove the interlock/upstop switch assembly (1,2) from the brake/clutch pedal bracket assembly by depressing the four plastic wing tabs on each switch.

INSTALLATION

NOTE: Proper switch harness routing is critical to switch durability. Note the harness routing and location of fasteners intended to keep wires from contacting pedals.





1. Install switches (1,2) into the pedal bracket assembly Route harness as was prior to removal.
2. Install clutch and brake pedals to pedal bracket, and install pivot shaft and nut. Torque pivot shaft nut to 42 Nm (31 ft. lbs.).





3. Install brake/clutch pedal bracket assembly (1) into position. Install and tighten brake booster mounting nuts to 34 Nm (300 inch lbs.). Install and tighten pedal bracket-to-instrument panel nuts to 34 Nm (300 inch lbs.).
4. Install new stop lamp switch.





5. Connect brake booster rod to brake pedal. Install retainer clip (1).





6. Loosen adjustment screw (1) on clutch master cylinder pushrod. Gently lift clutch pedal upwards. Raising pedal with excessive force can damage the pedal upstop, causing excessive pedal travel.

NOTE: Inspect plastic retainer upon removal. If retainer is damaged in any way (broken/cracked), it MUST be replaced.

7. Connect clutch master cylinder pushrod to pedal pin and torque adjustment screw to 6 Nm (55 inch lbs.).
8. Connect interlock/upstop and stop lamp switch connectors.





9. Install left lower instrument panel bezel (2).
10. Connect battery negative cable.
11. Verify proper switch operation.