Correcting a customer complaint regarding clutch pedal play
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SERVICE INFORMATION
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Bulletin Nbr:
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412-9016
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Date:
...........
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SEPTEMBER 1995
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Market:
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US CA
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Correcting a customer complaint regarding clutch pedal play
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On 1994 and later 900 models equipped with manual transmissions, customers may complain that their car has excessive clutch pedal play or a clutch that engages too early (when the pedal is close to the floor). The following procedure will resolve such a complaint.
1994-98 900 models with manual gearbox
Washer, 2mm: 43 33 811
Moycote, 10g tube: 87 81 718
(or or silicone grease (source locally at marine supply stores)
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1.
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Pull the clutch lever forward 2-3 times (see item 1, figure 1). Listen for squeaking or any other unwanted noise.
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2.
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Move the main fuse box out of the way (see item 3, figure 2). This will enable you to easily reach the return spring.
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Important
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Jerking the return spring suddenly can damage the mechanism. In the next step, pull steadily on the return spring.
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3.
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Pull the return spring forward, away from the bulkhead (see item 2, figure 1), then release the spring.
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Note
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Pulling the return spring forward relieves tension on the self-adjusting mechanism and allows it to index itself.
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4.
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Check the free play in the clutch pedal. If it is 20mm or less, no further adjustment is necessary. If pedal free play is greater than 20 mm, perform Action 2.
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5.
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If you heard any squeaking or unwanted noise when you pulled the clutch lever forward in step 1 or while working the clutch pedal up and down, apply Moycote to the cable’s plastic ring where it touches the clutch pedal.
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6.
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Move the main fuse box back in place.
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Note
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NOTE: Complete this action only if clutch pedal free play is greater than 20mm.
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1.
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Remove the clutch cable as described in Service Manual 4:1 ‘’Manual gearbox”, pages 412-2 and 412-3.
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2.
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Remove the self-adjusting device’s rubber damper and move it over the plastic ring (see item 4, figure 3).
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