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Clutch Pedal: Removal

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE UPPER INSTRUMENT PANEL SUB-ASSEMBLY 

    (See REMOVAL )

  2. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY RH  (See REMOVAL )
  3. SEPARATE MAIN BODY ECU (INSTRUMENT PANEL JUNCTION BLOCK) 
    1. Remove the 2 screws and separate the main body ECU.
  4. DISCONNECT CONNECTORS 
    1. Disconnect the clutch start switch connector and clutch switch connector.
  5. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS WITH HOLE PIN 
    1. Remove the clip and hole pin.
      Fig 1: Identifying Clip And Hole Pin
      G05388659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE CLUTCH PEDAL SUPPORT SUB-ASSEMBLY 
    1. Remove the 2 nuts, bolt and clutch pedal support assembly.
      Fig 2: Locating Clutch Pedal Support Sub-Assembly Bolt And Nuts
      G05388660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut from the clutch pedal support sub-assembly.
      Fig 3: Identifying Clutch Pedal Support Sub-Assembly Nut
      G05388661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE CLUTCH PEDAL STOPPER BOLT 
    1. Remove the clutch pedal stopper bolt from the clutch pedal support sub-assembly.
    Fig 4: Locating Clutch Pedal Stopper Bolt
    G05388662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE CLUTCH PEDAL SPRING 
    1. Mount the clutch pedal in a soft jaw vise.
    2. While the clutch pedal is fully depressed, remove the clutch pedal spring.
    3. Remove the clutch pedal spring holder from the clutch pedal support sub-assembly.
  9. REMOVE PEDAL WITH HOOK SPRING 
    1. Remove the pedal with hook spring.
  10. REMOVE CLUTCH PEDAL SUB-ASSEMBLY 
    1. Remove the bolt and nut.
    2. Remove the clutch pedal sub-assembly from the clutch pedal support.
    3. Remove the spring bushing from the clutch pedal.
    Fig 5: Locating Clutch Pedal Sub-Assembly
    G05388663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE CLUTCH PEDAL PAD 
    1. Remove the clutch pedal pad from the clutch pedal sub-assembly.
  12. REMOVE CLUTCH PEDAL BUSHING 
    1. Remove the 2 bushings from the clutch pedal.
      Fig 6: Identifying Clutch Pedal Bushing
      G05388664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE NO. 1 CLUTCH PEDAL CUSHION 
    1. Using needle-nose pliers, remove the 2 No. 1 cushions from the clutch pedal sub-assembly.
      Fig 7: Identifying No. 1 Clutch Pedal Cushion
      G05388665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS BUSHING 
    1. Using an 8 mm hexagon wrench and a hammer, remove the clevis bushing from the clutch pedal sub-assembly.
  15. REMOVE CLUTCH SWITCH ASSEMBLY 
    1. Remove the nut and clutch switch assembly from the clutch pedal support sub-assembly.
  16. REMOVE CLUTCH START SWITCH ASSEMBLY 
    1. Remove the nut and clutch start switch assembly from the clutch pedal support sub-assembly.
      Fig 8: Identifying Clutch Start Switch Assembly
      G05388666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE NO. 1 PEDAL SPRING HOOK 
    1. Using needle-nose pliers, remove the No. 1 pedal spring hook from the clutch pedal support sub-assembly.
      Fig 9: Identifying No. 1 Pedal Spring Hook
      G05388667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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