Clutch Pedal - Clicking/Popping Noise

9234chrysler03

NO.: 06-02-92

GROUP: Clutch

DATE: Jun.15,1992


SUBJECT:
Clutch Pedal Noise


MODELS:

1990 (AL) Omni/Horizon
1990-1991 (AQ) Maserati
1990-1992 (AA) Acclaim/Spirit
(AG) Daytona
(AJ) LeBaron Coupe/LeBaron Convertible
(AP) Sundance/Shadow/Shadow Convertible
(AS) Caravan/Caravan C/V/Voyager


SYMPTOM/CONDITION:

Some customers may experience a loud "clicking" or "popping" noise coming from the clutch pedal when the pedal is depressed. This may occur each time the pedal is depressed, but is more likely to be intermittent.


DIAGNOSIS:

Verify the "clicking" or "popping" noise can be heard by depressing the clutch pedal several times.


PARTS REQUIRED:

1 Auto Clutch Cable Adjust Spring 4188653


REPAIR PROCEDURE:

This repair involves replacement of the auto clutch cable adjuster spring.

1. With the ignition key in the OFF position, remove the clutch cable from the release lever at the transaxle. This can be done by pulling on the end of the clutch cable with pliers and removing the cable attachment clip.





2. Pull up slightly on the clutch pedal. This will relieve the spring tension on the positioner adjuster located on the back of the clutch pedal, see Figure 1.


3. Remove the auto clutch cable adjuster spring from the back of the clutch pedal, see Figure 1. The lower legs of the spring are bent to lock on the back of the pedal. It will be necessary to push the locked leg sections over the bottom edge of the clutch pedal where the spring is located.





4. Check the spring for cracks. If cracks are evident, replace the spring. Measure the spring tension dimension, see Figure 2, with the spring in a relaxed position.


5. If the spring is out of the dimension, shown in Figure 2, replace the spring with PN 4188653.

6. Install the auto clutch adjuster spring on the back of the clutch pedal. Caution should be used as to not bend or damage the spring during installation.

7. Lube the teeth of the positioner adjuster, using Lubriplate (PN 4549615) or equivalent, on the back side of the clutch pedal.

8. Install the clutch cable to the release lever at the transaxle.

9. Push and lift up on the clutch pedal 2 or 3 times to allow the adjuster mechanism to reset the clutch cable.


POLICY:
Reimbursable within the provisions of the warranty.


TIME ALLOWANCE
Labor Operation No. 06-50-15-91 .............................. 0.3 Hrs.


FAILURE CODE:
68 -Noisy