14. Underneath the vehicle, ensure that the inner cable is still attached to the clutch fork. If it has come undone, go back and unhook the cable from the quadrant, then reattach it at the clutch fork and complete Step 13 again.
15. Extend the firewall adjuster until there is some tension in the cable. Test the pedal operation. If it feels too stiff, adjust 5-10 turns clockwise (thread the adjuster into the firewall) to reduce the tension and lower the point of engagement. If it feels too loose, adjust 5-10 turns counterclockwise (thread the adjuster out of the firewall) to increase the tension and raise the point of engagement. Alternate between adjusting the tension and testing the pedal until it operates smoothly and feels normal. See Step 17 for notes about the ideal adjustment.
• If the pedal feels extremely stiff, check that the cable has been properly routed and that it does not have any tight bends or interference with the vehicle.
• If the pedal drops to the floor with no resistance, check that the inner cable is still connected to the quadrant and clutch fork.
NOTE: If you removed the driver’s seat, it can now be reinstalled. 16. Remove the masking tape from the clutch fork. Reinstall the clutch fork dust cover and lower the vehicle back to the ground.
17. Place your hand on the clutch pedal pad and press down lightly and release. You will hear a slight clink when the pedal is released. This is the sound of the clutch quadrant contacting its upwards stop. Rotate the firewall adjuster counter-clockwise to increase the tension on the clutch cable some. Press down on the clutch pedal pad with 3-5 lb of force. You should still hear a slight clink and feel the quadrant come on and off the stop. If the pedal didn’t come off of the stop with 3-5 lb of force, decrease the cable tension some with the firewall adjuster. Repeat this process until the clutch pedal just comes off of the stop with 3-5 lb of force.
Remember to periodically readjust the clutch cable tension as the clutch wears. This is very important. As the clutch friction disc wears, the clutch cable will become tighter, engaging the clutch more and more. If the cable tension is not reduced as the clutch wears, the clutch will eventually start slipping, which leads to greater wear, more cable tension and even faster wear.
• If the point of engagement is too high (too far from the floor): it is likely that (even with the pedal released), the clutch is not fully engaged. This will cause clutch slippage, resulting in dramatically increased wear of the disc and heat damage to the flywheel and pressure plate.
• If the point of engagement is too low (below the point where the pedal hits the floor): it is likely that you will not be able to fully disengage the clutch. This will damage the transmission and make it more difficult or impossible to change gear.