Clutch Pedal Assembly: Service and Repair

Clutch Pedal Replacement

Removal Procedure





1. Remove the driver's side knee bolster and deflector.
2. Disconnect and reposition the junction block.
3. Disconnect the clutch pedal position switch electrical connector (1).
4. Push the clutch pedal in and squeeze the pushrod bushing tabs in, in order to release the pushrod bushing from the clutch pedal.





5. If equipped with a NV 3500 or NV 4500 transmission, disconnect the clutch master cylinder to clutch actuator cylinder quick connect fitting.
6. Remove the clutch master cylinder clip from the brake pressure module valve pipe.





7. If equipped with a ZF S6-650 transmission, disconnect the clutch master cylinder to clutch actuator cylinder quick connect fitting.





8. Rotate the clutch master cylinder 45 degrees clockwise to the unlocked position.

Important: Complete removal of the clutch master cylinder is not required.

9. Pull the clutch master cylinder out until the pushrod socket is not touching the clutch pedal.





10. Remove the clutch pedal to clutch pedal bracket bolt.





11. Remove the clutch pedal to brake module bolts.
12. Remove the clutch pedal sub-assembly.

Installation Procedure





1. Install the clutch pedal sub-assembly.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the clutch pedal to brake module bolts.
^ Tighten the clutch pedal to brake module bolts to 50 Nm (37 ft. lbs.).





3. Install the clutch pedal to clutch pedal bracket bolt.
^ Tighten the clutch pedal to clutch pedal bracket bolt to 36 Nm (27 ft. lbs.).





4. Push the clutch master cylinder in until the pushrod socket is touching the clutch pedal.
5. Push in and rotate the clutch master cylinder 45 degrees counterclockwise to the locked position.





6. If equipped with a ZF S6-650 transmission, connect the clutch master cylinder to clutch actuator cylinder quick connect fitting.





7. If equipped with a NV 3500 or NV 4500 transmission, connect the clutch master cylinder to clutch actuator cylinder quick connect fitting.
8. Install the clutch master cylinder clip to the brake pressure module valve pipe.





9. Apply light pressure to the clutch pedal to couple the pushrod socket to the clutch pedal.
10. Connect the clutch pedal position switch electrical connector (1).
11. Pump the clutch pedal 3 time prior to starting the vehicle to ensure connection is complete.
12. Position and connect the junction block.
13. Install the driver's side knee bolster and deflector.