Clutch pedal (Hyundai Sonata EF)

Checking and adjusting the clutch pedal

1. Measure the height "B" of the clutch pedal above the floor (from the top of the pedal pad to the driver's footwell) and the free play of the rod.

• Height of pedal "B": 180.5±0.3 mm
• Free travel of rod "A": 1-3 mm

2. If the free travel of the rod does not correspond to the technical data, then adjust it as follows:

• a) Loosen the lock nut and adjust the height by turning the adjusting bolt. Then secure the bolt by tightening the lock nut.

Note: After adjustment, screw the clutch pedal switch until it touches the pedal travel limiter and then tighten the lock nut.

• Tightening torque: 8-10 Nm
• b) Turn the stem until the required stem clearance is set, then secure the stem with the lock nut.

Caution: Be careful not to push the plunger into the clutch master cylinder when making adjustments.

3. After completing the adjustments, make sure that the free play "C" of the clutch pedal, measured at the top of the pedal pad, corresponds to the nominal value.

• Nominal value "C": 6-13 mm

4. If the free travel with the clutch disengaged is outside the nominal value range, this may be caused by air entering the clutch hydraulic drive or a fault in the clutch release drive master cylinder, or a fault in the clutch itself. Bleed the clutch release drive, if necessary, disassemble and check the clutch release drive master cylinder or the clutch itself.

Removal

1. Remove the cotter pin, remove the pin and washer, disconnect the master cylinder rod fork from the clutch pedal.



2. Disconnect the return spring.

3. Loosen the nut, remove the clutch pedal shaft and remove the clutch pedal assembly.

4. Remove the clutch pedal return spring and take out the bushings.

Examination

1. Check the clutch pedal bushings and axle for wear.

2. Check the clutch pedal for deformation (bending and twisting).

3. Check the return spring for damage or deformation.

4. Check the clutch pedal pad for damage and wear.

5. Check the switch on the clutch pedal.

• a) Remove the switch.
• b) Measure the presence of conductivity between the terminals of the switch connector

Installation

1. Apply grease to the bushings and clutch pedal.

• Lubrication: SAE J310a Chassis Grease, NLGI #1

2. Install the clutch pedal shaft and tighten the nut.

• Tightening torque: 25-35 Nm

3. Apply grease to the pin and washer in the clutch pedal joint.

• Lubrication: SAE J310, NLGI No.2 hub bearing grease

4. Connect the rod fork to the clutch pedal.

5. Adjust the free travel of the rod.