Pedal, Assembly, Controls Group 29

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Sophia McBride
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1 Pedal, Assembly, Controls Group 29 ( Job No. Removal and Installation of Pedal Assembly 29 1 Repair of Pedal Assembly 29-2 Removal, Installation and Repair of Accelerator Pedal 29 3 Removal, Installation and Repair of Manual Throttle Control /1

2 Removal and Installation of Pedal Assembly 29-1 I, Removal and installation in non-tiltable cabs Up to chassis nos Protect vehicle against rolling off (pull handbrake). 2 Remove engine hood. 3 Remove intake pipe. 4 Remove left-hand heater hose. 5 Detach brake fluid line from clutch master cylinder and brake master cylinder. Note: Catch escaping brake fluid. Brake fluid should not come into contact with the paintwork as it destroys the finish. 6 Detach stop light cable from brake master cylinder stop light switch. 7 Remove dust caps from piston rods. 8 Unscrew fasteners for clutch master cylinder and bracket as well as brake master cylinder and bracket. Remove clutch master cylinder and brake master cylinder from the front. 9 Unscrew fasteners for bracket, top rear. Remove bracket inwards together with pedal and piston rod. 10 Repair pedal assembly as described under Job No To install, reverse the removal procedure. Note: Do not attach return spring before the clutch master cylinder and the brake master cylinder have been installed. When the clutch and brake pedals are in neutral position, the piston rod to the clutch master cylinder and brake master cylinder should have approx. 1 mm play on the piston. This free travel of the pedal should be adjusted by the adjusting screw (eccentric screw) by which the piston rod is linked to the pedal. It should amount to approx. 10 mm, measured at the upper edge of the pedal. The clutch pedal free travel should, however, only be adjusted between the clutch slave cylin der and the clutch lever. Job No. 25-2, 25-5 and 25-6, item II. II* Removal and installation in tillable cabs As of chassis nos Protect vehicle against rolling off (pull handbrake). 2 Remove engine hood. 3 Detach brake fluid line from clutch master cylinder. Note: Catch escaping brake fluid. Brake fluid should not come into contact with the paint work since it destroys the finish. 4 Remove dust cap from piston rod of clutch master cylinder, as well as line between brake fluid reservoir and brake master cylinder. 5 Unscrew fasteners of clutch master cylinder and bracket. Remove clutch master cylinder from the front. 6 Unscrew fasteners for clutch and brake pedal bracket at the rear top. Unscrew front mounting nuts for brake pedal bracket. 7 Remove bracket with pedal and piston rod inwards. 8 For repair of pedal assembly see Job No To install, reverse the removal procedure. Note: Do not attach return spring before the clutch master cylinder has been installed. When the clutch and brake pedals are in neutral posit ion, the piston rod to the clutch master cylinder 29-1/1

3 and single-chamber brake booster must have should amount to approx. 10 mm, measured at approx. 1 mm play on the piston. the upper edge of the pedal. The cluch pedal free travel should, however, This free travel of the pedal should be adjusted only be adjusted between the clutch slave cylinby the adjusting screw (eccentric screw) by der and the clutch lever. Job No. 25-2, 25-5, which the piston rod is linked to the pedal. \\ and 25-6, item II. 29-1/2

4 Repair of Pedal Assembly 1 Remove pedal from bracket: Unscrew hexagonal nut. Pull hexagonal bolt from pedal mounting. 2 Remove bearing sleeve from bearing bushes. 3 Remove pedal from bracket. 4 If necessary, remove piston rod. a) Unscrew hexagonal nut. Remove it together with lock washer. b) Pull adjusting screw (eccentric screw) from pedal. c) Remove bearing bushes. 5 Carefully check all parts for wear and dam age. Parts that are damaged or worn beyond the wear limit must not be re-used. 6 If necessary, replace bearing bushes: The iwo bearing bushes in the pedal are made of plastic. They limit the lateral play of the pedal as well as the radial play to the bearing sleeve. If a distinct play is noticed, both bearing bushes must be replaced by new ones The new bearing bushes should be an inter ference fit. Install them using suitable arbor of approx. 19 mm dia. and support. Do not upset them. If any remachining is necessary on the bearing bushes, be sure to use machine reamer at low speed, at the same time adding some oil for lubrication. High speeds would lead to heat seizure between the bearing bushes and the reamer. 7 To reassemble, reverse the disassembly pro cedure. Note: The maximum lateral play of the pedal is 1,5 mm. Apply a few drops of oil to the bearing bush to protect it against corrosion. Note: In UNIMOGs with tiltable cabs, slight alterations were made on several pedal as sembly components starting with chassis nos A modified piston rod for the clutch master cy linder has been installed as of chassis nos /1

5 Removal, Installation and Repair of Accelerator Pedal 29-3 I. In non-tihable cabs Up to chassis nos Remove outer and inner engine hood. 2 Force off linkage on pedal shaft lever arm from ball pin on underside of vehicle and pull it off from bell crank with button-head bolt. 3 Unscrew bell crank hex.-hd. bolt and detach bell crank. 4 Detach manual throttle control cable from bell crank. Remove bell crank from below. 5 Remove accelerator pedal inwards from bearing. 6 Loosen fasteners and remove bearing from cab. 7 Detach return spring from holder on crankcase. 8 Remove pull rod between control lever and injection pump adjusting lever. 9 Remove control lever from control shaft. Re move control shaft. 10 Carefully checkall parts forwearand dam age. Parts showing damage or wear exceed ing the wear limit must not be re-used. 11 If the damper ring has become soft or soak ed, it must be replaced. 12 If necessary, replace bearing bushes: The two bearing bushes in the accelerator pedal are made of plastic material. They limit the la teral movement of the pedal as well as the rad ial play of the pedal in relation to the pedal shaft. If there is a noticeable play, replace both bearing bushes. 13 To install, reverse the removal procedure, watching in particular the following points: a) Apply molybdenum disulfide paste (Molykote paste G Rapid) to pedal shaft when it is installed. b) Protect pedal shaft bearing against corros ion by adding a few drops of oil. c) The accelerator pedal adjustment is made on the control shaft lever arm, or linkage ball socket. II. Intiltablecabs Starting with chassis nos Remove outer and inner engine hood. 2 On underside of chassis, disconnect linkage from control shaft and follower lever. 3 Unscrew hexagon nut from bell crank shaft and pull off accelerator pedal. 5 If necessary, remove bearing bushes for bell crank lever. 6 Remove guide roller from bell crank. 7 If necessary, remove follower lever. 8 Detach return spring from holder on crankcase. 9 Remove rod between control lever and ad justing lever of injection pump. 4 Detach bell crank return spring and throttle control cable. Remove bell crank. 10 Remove control lever from control shaft. Remove control shaft. 29-3/1

6 11 Carefully check all parts for wear and dam age. Parts showing damage or wear exceed ing the wear limit must not be re-used. 12 If necessary, replace guide roller. 13 If necessary, replace bearing bushes: The two bearing bushes in the bell crank shaft bearing are made of plastic material. They limit the lateral play of the bell crank as well as the radial play of the bell crank in relation to the bell crank shaft. If there is a noticeable play, replace both bearing bushes. 14 To install, reverse the removal procedure, watching in particular the following points: a) Apply molybdenum disulfide paste (Molykote paste G Rapid) to bell crank shaft when it is installed. b) Protect bell crank shaft against corrosion by adding a few drops of oil. c) The accelerator pedal adjustment is made on the control shaft lever arm. 29-3/2

7 Removal, Installation and Repair 1 Remove outer and inner engine hood. 2 Detach cable from clamping piece. Remove clamping piece and ball half. Note: The clamping piece and ball half have been replaced by an adjusting ring. 3 Remove intake pipe. Note: Only up to chassis nos Remove left-hand heater hose. Note: Only up to chassis nos Remove protective cap for manual control. 6 Loosen slotted nut and remove it with tooth ed disc. of Manual Throttle Control Working from front end of cab, remove spring retainer, disc spring, thrust washer, frict ion disc, draw lever and friction disc from bearing flange after unscrewing the two fast ening nuts. 10 Remove bearing flange and pawl inwards. 11 If the manual control moves too easily, re place both friction discs. 12 If manual control is too stiff, check whether the notch lever was distorted by force. There is also the possibility that the draw lever shaft is bent. If the notch lever is bent or distorted, it must be replaced since it would break when being reconditioned. 13 Carefully check all parts for wear and dam age. Parts that show damage or wear exceed ing the wear limit must not be re-used. 14 To install, reverse the removal procedure. Note: The slotted nut has been replaced by a hexagonal nut. 7 Remove bell. Mind the spring under it. Note: Starting with chassis nos Remove detent lever with hub and cylind rical pin from shaft. several parts of the manual control system have been slightly modified. 29-4/1

CLUTCH Nissan 240SX DESCRIPTION PEDAL HEIGHT & FREE PLAY ADJUST CLUTCH ASSEMBLY R & I Clutch. Pathfinder, Pickup, 240SX, 300ZX

CLUTCH Nissan 240SX DESCRIPTION PEDAL HEIGHT & FREE PLAY ADJUST CLUTCH ASSEMBLY R & I Clutch. Pathfinder, Pickup, 240SX, 300ZX CLUTCH 1990 Nissan 240SX 1990 Clutch Pathfinder, Pickup, 240SX, 300ZX DESCRIPTION Clutch is of dry, single disc type, with a diaphragm spring type pressure plate. Clutch release bearing is prelubricated.