1994 Mazda B4000 SE. CRUISE CONTROL SYSTEM 1994 ACCESSORIES/SAFETY EQUIPMENT Mazda Cruise Control System
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- Piers Cannon
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1 DESCRIPTION Cruise control system consists of control switches located on steering wheel, servo throttle actuator assembly, speed sensor mounted on transmission (transfer case on 4WD), clutch switch (M/T), speed control amplifier located above glove box, and stoplight switch and vacuum dump valve located on brake pedal. OPERATION ENGAGING SYSTEM System will not operate at speeds less than 30 MPH. When ON/OFF switch is set to ON position, system is ready to receive an input from SET/ACCEL switch. When SET/ACCEL switch is momentarily pressed, system will engage and vehicle speed will be maintained. DISENGAGING SYSTEM Press brake pedal, press clutch pedal (M/T), turn control switch off, or turn on hazard lights. RESUMING SET SPEED After disengaging system, press RSM (resume) switch to resume set speed. DECREASING SPEED Disengage system and reset speed as desired, or press CST (coast) switch until vehicle slows to desired speed, then release CST switch. INCREASE SPEED Press accelerator pedal until vehicle speed is as desired, then press SET/ACCL switch. Also, to automatically increase speed, press SET/ACCL switch until vehicle speed is as desired, then release switch. ADJUSTMENTS SERVO CABLE Remove servo cable retaining clip from throttle lever. Disengage cable from throttle. Set engine at hot idle. Pull servo cable to take up slack. Ensure cable does not hold throttle open at idle. While holding cable, insert cable retaining clip. VACUUM DUMP VALVE Firmly pull brake pedal upward (fully released). Push dump valve toward brake pedal until valve collar bottoms against pad on brake pedal. CIRCUIT TESTING
2 Vehicles with computerized engine controls should be tested for stored computer codes. Codes and related problems must be repaired prior to cruise control diagnosis and repair. For additional information, see appropriate G - TESTS W/ CODES article in ENGINE PERFORMANCE section below. TESTS W/CODES (for B2300 & B3000) TESTS W/CODES (for B4000) CONTROL SWITCH & CIRCUIT DO NOT use a test light to perform the following tests. 1. Step on brake pedal. Check for proper stoplight operation. Repair stoplight circuit as necessary. See STOPLIGHT SWITCH & CIRCUIT TEST. Press horn button. If horn does not sound, repair horn circuit. See HORN RELAY CIRCUIT TEST. If stoplights and horn operate properly, go to next step. 2. Turn ignition off. Locate amplifier 6-pin connector behind right side of dash, above glove box. Backprobe connector using Digital Volt-Ohmmeter (DVOM). Check continuity between Black wire terminal of amplifier connector and ground. Repair Black wire as necessary and retest. If Black wire is okay, go to next step. 3. Turn ignition on. Measure voltage between ground and Dark Blue/Light Green wire terminal of amplifier connector. If battery voltage is present, go to next step. If battery voltage is not present, check cruise control fuse and circuit. Repair or replace as necessary. 4. Step on brake pedal. Measure voltage at Light Green wire terminal of amplifier connector. If stoplights illuminate and battery voltage is present, go step 6). If stoplights illuminate and battery voltage is not present, go to next step. 5. Check continuity between stoplight switch and amplifier. If continuity exists, replace amplifier and retest. If continuity does not exists, repair wiring between stoplight switch and amplifier as necessary. 6. Measure voltage between ground and Light Blue/Black wire terminal of steering wheel control switch 4- pin connector. If 7.8 volts is present, go to step 9). If 7.8 volts is not present, go to next step. 7. Measure voltage between ground and Dark Blue/Light Green wire terminal of amplifier connector. If zero volts is present, go to step 8). If battery voltage is present, check if ON button is sticking. If ON button is okay, replace amplifier and retest. If ON button is not okay, repair or replace ON button as necessary. 8. Check for a short to ground in Light Blue/Black wire between amplifier and steering column brush assembly. If a short circuit exists, repair wiring as necessary. If a short circuit does not exist, replace amplifier and retest. 9. Connect positive voltmeter lead to Light Blue/Black wire terminal of amplifier connector and negative voltmeter lead to Black wire terminal of amplifier connector. Measure voltage while turning steering wheel 1/4 turn left and right with specified control switch pressed. See CONTROL SWITCH VOLTAGE table. CONTROL SWITCH VOLTAGE Switch Position Approx. Voltage (Volts) No Button Pressed 7.8 ON 12.0
3 OFF 0 RESUME (RSM) 6.5 SET/ACCEL 4.5 COAST (CST) If voltages are as specified, go to step 16). If voltages are not as specified, turn ignition off. Disconnect amplifier 6-pin connector. Connect positive lead of ohmmeter to Light Blue/Black wire terminal of amplifier connector and negative lead to Black wire terminal of amplifier connector. Measure resistance while turning steering wheel 1/4 turn left and right with specified control switch pressed. See CONTROL SWITCH RESISTANCE table. CONTROL SWITCH RESISTANCE Switch Position Ohms OFF 0-1 SET/ACCEL COAST (CST) RESUME (RSM) If resistances are as specified, replace amplifier and go to step 9). If resistances are not as specified, remove horn pad (or air bag if equipped). Disconnect steering wheel control switch 4-pin connector. Connect positive lead of ohmmeter to Light Blue/Black wire terminal of control switch connector and negative lead to Yellow/Light Green wire terminal of control switch connector. Measure resistance. If resistance measures 0-1 ohm, go to next step. If resistance does not measure 0-1 ohm, replace control switch assembly. 12. Connect positive lead of ohmmeter to Light Blue/Black wire terminal of control switch connector and negative lead to Black wire terminal of control switch connector. Measure resistance with specified control switch pressed. See CONTROL SWITCH RESISTANCE table. If resistances are as specified, go to next step. If resistances are not as specified, replace control switch assembly. 13. Remove steering wheel. Check continuity between Light Blue/Black wire and Black wire terminals of amplifier 6-pin connector and steering column brush assembly. If continuity does not exist, go to next step. If continuity exists, go to step 15). 14. Check continuity between steering column brush assembly 3-pin connector and brush assembly. Also check continuity between steering column brush assembly 3-pin connector and amplifier 6-pin connector. Repair wiring or replace brush assembly as required. 15. Clean brush assembly and slip rings with solvent, then lubricate with cruise control slip ring grease. Reinstall steering wheel and horn pad (or air bag if equipped), then go to step 2). 16. Connect ohmmeter between Gray/Black wire terminal and Pink/Orange wire terminal of amplifier 6-pin connector. Measure resistance. If resistance does not measure ohms, go to next step. If resistance measures ohms, wiring is okay. Not all speed sensor problems can be detected with resistance checks. Substitution with a known good speed sensor may be necessary. 17. Check continuity between Gray/Black wire terminal of amplifier connector and Gray/Black wire terminal
4 of speed sensor 2-pin connector. If continuity does not exist, repair wiring as necessary. If continuity exists, check speed sensor. See SPEED SENSOR TEST. HORN RELAY CIRCUIT DO NOT disconnect horn relay connector to perform the following tests. 1. Locate horn relay beneath lower center of dash, to the right of steering column. Measure voltage between ground and Yellow/Light Blue wire of horn relay connector. If battery voltage is not present, check fuse and/or Yellow/Light Blue wire for open circuit. Repair or replace as necessary. If battery voltage is present, go to next step. 2. Measure voltage between ground and Yellow/Light Blue wire of horn relay connector while pressing horn button. Voltage should drop to about zero volts and horn should sound. If horn does not sound and voltage does not drop to about zero volts, go to next step. If horn sounds and voltage drops to about zero volts, horn relay is okay. 3. Measure voltage between ground and Yellow/Light Green wire of horn relay connector. If battery voltage is not present, replace horn relay and retest. If battery voltage is present, go to next step. 4. Measure voltage between ground and Yellow/Light Green wire of horn relay connector. If horn does not sound, go to next step. If horn sounds, replace horn pad. 5. Ground Yellow/Light Green wire of horn relay connector. Measure voltage between ground and Dark Blue wire of horn relay connector. If battery voltage is present, service horn. If battery voltage is not present, replace horn relay and retest. STOPLIGHT SWITCH & CIRCUIT 1. Step on brake pedal and check for proper stoplight operation. If stoplights illuminate, go to next step. If stoplights do not illuminate, check stoplight fuse, bulbs, stoplight switch and stoplight circuit. Repair or replace as necessary. Perform VACUUM DUMP VALVE TEST. If stoplights illuminate, but a maximum brake pedal pressure of 6 lbs. (2.7 kg) is required to illuminate stoplights, check brake pedal actuation and stoplight switch. Repair or replace as necessary. 2. Measure voltage between ground and Dark Blue/Light Green wire terminal of amplifier 6-pin connector (amplifier main power supply). Step on brake pedal until stoplights illuminate. Measure voltage between ground and Light Green wire terminal of amplifier connector. Release brake pedal and measure voltage between ground and Light Green wire terminal of amplifier connector again. 3. When brake pedal is pressed, difference in voltage between Dark Blue/Light Green wire terminal and Light Green wire terminal of amplifier connector should be less than 1.5 volts. When brake pedal is released, zero volts should be present at Light Green wire terminal of amplifier connector. If voltage measurements are as specified, stoplight switch and circuit are okay. If voltage measurements are not as specified, check stoplight circuit to find source of high resistance. COMPONENT TESTING SPEED SENSOR Not all speed sensor problems can be detected with resistance checks.
5 1. Locate speed sensor on transmission (transfer case for 4WD). Disconnect speed sensor 2-pin connector. Measure resistance between wire terminals of speed sensor connector. If resistance does not measure ohms, replace speed sensor. If resistance measures ohms, go to next step. 2. Road test vehicle and observe speedometer needle. If speedometer needle wavers, replace speed sensor. If speedometer needle does not waver, speed sensor is okay. SERVO 1. Locate amplifier 8-pin connector behind right side of dash, above glove box. Disconnect amplifier 8-pin connector. Measure resistance between specified wire terminals of amplifier connector. See SERVO RESISTANCE table. If resistances are as specified, go to next step. If resistances are not as specified, go to step 3). SERVO RESISTANCE Wire Color Ohms Orange/Yellow - Gray/Black Orange/Yellow - White/Pink Purple/Light Blue - Brown/Light Green 35,000-70,000 Purple/Light Blue - Yellow/Red 15,000-35,000 Yellow/Red - Brown/Light Green 15,000-35, Compare resistance measurement between Purple/Light Blue wire terminal and Yellow/Red wire terminal of amplifier connector with resistance measurement between Yellow/Red wire terminal and Brown/Light Green wire terminal of amplifier connector. If resistance measurements differ more than 5000 ohms and vehicle has a surging problem, go to next step. If resistance measurements do not differ more than 5000 ohms and vehicle does not have a surging problem, go to step 4). 3. Disconnect servo 6-pin connector. Ensure terminals are clean. Measure resistance between specified wire terminals of servo connector. See SERVO RESISTANCE table. If resistances are as specified, check wiring for continuity. Repair as necessary. If resistances are not as specified, replace servo and retest. 4. Disconnect servo from amplifier. Start engine. Ensure vacuum to servo is at least 2.5 in. Hg. Connect battery positive lead to Orange/Yellow wire of servo. Connect White/Pink wire of servo to ground. Momentarily connect Gray/Black wire of servo to ground. 5. Servo arm should pull in and engine speed should increase when Gray/Black wire of servo is connected to ground. Disconnect White/Pink wire from ground. Servo should release. Replace servo if responses are not as specified. AMPLIFIER Substitution with a known good speed sensor may be necessary. To test for a malfunctioning amplifier, substitute a known good unit. CLUTCH SWITCH Disconnect clutch switch pigtail connector from cruise control harness. Connect ohmmeter to terminals No. 3
6 and 4 of clutch switch connector. SeeFig. 1. With clutch pedal pressed, an open circuit should be indicated. With clutch pedal released, resistance should measure less than 5 ohms. Replace clutch switch if resistances are not as specified. Fig. 1: Identifying Clutch Switch Pigtail Connector Terminals Courtesy of FORD MOTOR CO. VACUUM DUMP VALVE 1. Locate vacuum dump valve on top of brake pedal. Check vacuum dump valve whenever brake application does not release cruise control. Ensure no more than 1/8" of plunger tip is extended when brake pedal is fully released. At servo unit, disconnect vacuum hose from dump valve to servo. Connect hand-held vacuum pump to hose. Apply vacuum to hose and dump valve. 2. If vacuum cannot be obtained, replace leaking hose or dump valve. Press brake pedal. Vacuum should be released. If vacuum is not released, check for kinks or obstructions in hose. Repair or replace hose as necessary. If hose is okay, adjust or replace dump valve. See VACUUM DUMP VALVE under ADJUSTMENTS. TROUBLE SHOOTING VISUAL INSPECTION Before proceeding to trouble shooting procedures, test drive vehicle to verify condition. If complaint is confirmed, make a visual inspection. Look for damaged or disconnected wires, blown fuses, broken or kinked speedometer cable, damaged or detached vacuum hoses, misadjusted servo cable, and rough operation of servo cable or throttle linkage. CRUISE CONTROL DOES NOT OPERATE 1. Visually inspect system. Check all electrical and vacuum connections. Repair as necessary. If all connections are okay, go to next step. 2. Step on brake pedal. Check for proper stoplight operation. See STOPLIGHT SWITCH & CIRCUIT
7 TEST under DIAGNOSIS & TESTING. Repair stoplight circuit as necessary. Press horn button. If horn does not sound, repair horn circuit. See HORN RELAY CIRCUIT TEST under DIAGNOSIS & TESTING. If stoplights and horn operate properly, go to next step (M/T) or go to step 4) (A/T). 3. Check clutch switch. See CLUTCH SWITCH TEST under DIAGNOSIS & TESTING. Service clutch switch as necessary. If clutch switch operates properly, go to next step. 4. Check servo cable for proper adjustment and operation. See SERVO CABLE under ADJUSTMENTS. Adjust servo cable as necessary. If servo cable operates properly, go to next step. 5. Check for vacuum at servo. Minimum vacuum for normal servo operation is 2.5 in. Hg. If there is no vacuum, go to next step. If vacuum is okay, go to step 7). 6. Check vacuum dump valve. See VACUUM DUMP VALVE TEST under DIAGNOSIS & TESTING. Service vacuum dump valve as necessary. If vacuum dump valve is okay, check vacuum source and hoses. 7. Check all control switches. See CONTROL SWITCH & CIRCUIT TEST under DIAGNOSIS & TESTING. Service control switches as necessary. If control switches are okay, go to next step. 8. Check servo. See SERVO TEST under DIAGNOSIS & TESTING. Tap servo body lightly while testing. Replace servo if defective. If servo is okay, go to next step. 9. Check speed sensor. See SPEED SENSOR TEST under DIAGNOSIS & TESTING. Replace speed sensor if defective. If speed sensor is okay, check amplifier. See AMPLIFIER TEST under DIAGNOSIS & TESTING. Replace amplifier if defective. If amplifier is okay, check wiring and all electrical and vacuum connections. Repair as necessary. CRUISE CONTROL OPERATES INTERMITTENTLY 1. Road test vehicle to verify condition. Note when intermittent condition occurs. 2. Inspect all electrical and vacuum connections. Repair as necessary. If condition occurs while cruising, go to next step. If condition occurs while operating control switches or while turning steering wheel, go to step 5). 3. Check for vacuum at servo. Minimum vacuum for normal servo operation is 2.5 in. Hg. If there is no vacuum, service vacuum supply. If vacuum is okay, go to next step. 4. Check servo. See SERVO TEST under DIAGNOSIS & TESTING. Tap servo body lightly while testing. Replace servo if defective. If servo is okay, substitute known good amplifier, then go to next step. 5. Check all control switches. See CONTROL SWITCH & CIRCUIT TEST under DIAGNOSIS & TESTING. Service control switches as necessary. Also service steering column brush assembly and slip rings as necessary. If control switches are okay, check amplifier. See AMPLIFIER TEST under DIAGNOSIS & TESTING. Replace amplifier if defective. If amplifier is okay, check wiring and all electrical and vacuum connections. Repair as necessary. CRUISE CNTRL OPERATES - DOES NOT RESUME, ACCELERATE OR COAST 1. Visually inspect system. Check all electrical and vacuum connections. Repair as necessary. If all connections are okay, go to next step. 2. Check all control switches. See CONTROL SWITCH & CIRCUIT TEST under DIAGNOSIS & TESTING. Service control switches as necessary. If control switches are okay, go to next step. 3. Check servo. See SERVO TEST under DIAGNOSIS & TESTING. Tap servo body lightly while testing.
8 Replace servo if defective. If servo is okay, check amplifier. See AMPLIFIER TEST under DIAGNOSIS & TESTING. Replace amplifier if defective. If amplifier is okay, check wiring and all electrical and vacuum connections. Repair as necessary. SPEED CONTINUOUSLY VARIES (SURGES) 1. Check servo cable for proper operation and adjustment. See SERVO CABLE under ADJUSTMENTS. Adjust servo cable as necessary. If servo cable operates properly, go to next step. 2. Check servo. See SERVO TEST under DIAGNOSIS & TESTING. Tap servo body lightly while testing. Replace servo if defective. If servo is okay, go to next step. 3. Inspect speedometer cables for proper routing, sharp bends, or binding. Service cables as necessary. If speedometer cables are okay, go to next step. 4. Check speed sensor for free operation. Check for defective speedometer gear. Measure coil resistance. Coil resistance should be about 200 ohms. Measure speed sensor output voltage. Output voltage at 30 MPH should be volts AC with 4000 ohms resistance load. Replace speed sensor or speedometer gear if output voltage is not within specification. If output voltage is okay, go to next step. 5. Check speed sensor. See SPEED SENSOR TEST under DIAGNOSIS & TESTING. Replace speed sensor if defective. If speed sensor is okay, go to next step. 6. Check vacuum dump valve. See VACUUM DUMP VALVE TEST under DIAGNOSIS & TESTING. Service vacuum dump valve as necessary. If vacuum dump valve is okay, go to next step. 7. Check amplifier. See AMPLIFIER TEST under DIAGNOSIS & TESTING. Replace amplifier if defective. If amplifier is okay, check wiring and, all electrical and vacuum connections. Repair as necessary. CRUISE CONTROL DOES NOT DISENGAGE WHEN BRAKES ARE APPLIED 1. Step on brake pedal. Check for proper stoplight operation. See STOPLIGHT SWITCH & CIRCUIT TEST under DIAGNOSIS & TESTING. Repair stoplight circuit as necessary. If stoplights operate properly, go to next step. 2. Check vacuum dump valve. See VACUUM DUMP VALVE TEST under DIAGNOSIS & TESTING. Service vacuum dump valve as necessary. If vacuum dump valve is okay, go to next step. 3. Check servo. See SERVO TEST under DIAGNOSIS & TESTING. Tap servo body lightly while testing. Replace servo if defective. If servo is okay, go to next step. 4. Check amplifier. See AMPLIFIER TEST under DIAGNOSIS & TESTING. Replace amplifier if defective. If amplifier is okay, check wiring and all electrical and vacuum connections. Repair as necessary. SPEED WILL NOT SET 1. Check system fuses. Check servo cable for proper adjustment and operation. See SERVO CABLE under ADJUSTMENTS. Adjust servo cable as necessary. If servo cable operates properly, go to next step. 2. Visually inspect system. Check all electrical and vacuum connections. Repair as necessary. If all connections are okay, go to next step. 3. Check all control switches. See CONTROL SWITCH & CIRCUIT TEST under DIAGNOSIS & TESTING. Service control switches as necessary. If control switches are okay, go to next step.
9 4. Check vacuum dump valve. See VACUUM DUMP VALVE TEST under DIAGNOSIS & TESTING. Service vacuum dump valve as necessary. If vacuum dump valve is okay, go to next step (M/T), or to step 6) (A/T). 5. Check clutch switch. See CLUTCH SWITCH TEST under DIAGNOSIS & TESTING. Service clutch switch as necessary. If clutch switch is okay, go to next step. 6. Step on brake pedal. Check for proper stoplight operation. See STOPLIGHT SWITCH & CIRCUIT TEST under DIAGNOSIS & TESTING. Repair stoplight circuit as necessary. If stoplights operate properly, go to next step. 7. Check servo. See SERVO TEST under DIAGNOSIS & TESTING. Tap servo body lightly while testing. Replace servo if defective. If servo is okay, go to next step. 8. Check speed sensor. See SPEED SENSOR TEST under DIAGNOSIS & TESTING. Replace speed sensor if defective. If speed sensor is okay, check amplifier. See AMPLIFIER TEST under DIAGNOSIS & TESTING. Replace amplifier if defective. If amplifier is okay, check wiring and all electrical and vacuum connections. Repair as necessary. CRUISE CONTROL DOES NOT DISENGAGE WHEN CLUTCH PEDAL IS PRESSED (M/T) Verify cruise control system deactivates when stoplight switch is activated. Check clutch switch operation. See CLUTCH SWITCH TEST under DIAGNOSIS & TESTING. If clutch switch is okay, service clutch switch wiring. SPEED GRADUALLY INCREASES OR DECREASES AFTER SPEED IS SET 1. Ensure engine performs normally. Perform testing under SPEED DECREASES ON STEEP GRADES OR UNDER HEAVY LOADS. Check accelerator cable and servo cable for proper adjustment and operation. See SERVO CABLE under ADJUSTMENTS. Adjust accelerator and servo cables as necessary. If accelerator and servo cables operate properly, go to next step. 2. Check vacuum dump valve. See VACUUM DUMP VALVE TEST under DIAGNOSIS & TESTING. Service vacuum dump valve as necessary. If vacuum dump valve is okay, go to next step. 3. Check servo. See SERVO TEST under DIAGNOSIS & TESTING. Tap servo body lightly while testing. Replace servo if defective. If servo is okay, check amplifier. See AMPLIFIER TEST under DIAGNOSIS & TESTING. Replace amplifier if defective. If amplifier is okay, check wiring and all electrical and vacuum connections. Repair as necessary. SPEED DECREASES ON STEEP GRADES OR UNDER HEAVY LOADS Road test vehicle. Set speed to about 55 MPH. Proceed up steep grade. When speed decreases 4-6 MPH, press accelerator pedal. If vehicle can maintain set speed without downshift (downshift is okay with overdrive transmission), problem exists in cruise control system. Check servo cable and vacuum hoses. Also, check for faulty servo or amplifier. If vehicle cannot maintain set speed without downshift, cruise control system is okay. Check and service powertrain as necessary. REMOVAL & INSTALLATION CAUTION: When battery is disconnected, vehicle computer and memory systems
10 CRUISE CONTROL SWITCHES Removal & Installation 1. Disconnect negative battery cable. Remove horn pad retaining screws and remove horn pad (or air bag if equipped). Carefully disconnect control switch electrical connector from steering wheel. Remove horn pad and control switch assembly. 2. Remove cruise control switch retaining screws. Disconnect 2 additional electrical connectors from horn pad. Push through rear of horn pad and remove control switch assembly. To install control switch assembly, reverse removal procedure. Tighten retaining screws to 8-11 INCH lbs. ( N.m). SPEED SENSOR Removal & Installation Speed sensor is located on transmission (transfer case on 4WD). Disconnect speedometer cable from speed sensor. Disconnect speed sensor electrical connector. Remove retaining bolt. Remove speed sensor. To install, reverse removal procedure. Check speed sensor for proper operation. AMPLIFIER Removal & Installation Amplifier is located above glove box. Remove glove box and glove box courtesy light, if equipped. Disconnect amplifier electrical connector. Remove amplifier and bracket as an assembly. Separate amplifier from bracket. To install, reverse removal procedure. Check amplifier for proper operation. SERVO Removal & Installation Disconnect speed control servo cable from accelerator cable. Disconnect electrical connectors and vacuum hoses from servo. Remove servo retaining nuts. Carefully remove servo and cable assembly. To install, reverse removal procedure. Adjust servo cable. See SERVO CABLE under ADJUSTMENTS. VACUUM DUMP VALVE Removal & Installation may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION section before disconnecting battery. Vacuum dump valve is located at brake pedal lever. Disconnect vacuum hose from vacuum dump valve. Remove vacuum dump valve from bracket. To install, reverse removal procedure. Adjust vacuum dump valve. See VACUUM DUMP VALVE under ADJUSTMENTS.
11 STOPLIGHT SWITCH Since switch side plate nearest brake pedal is slotted, it is not necessary to remove vacuum booster input rod and one bushing spacer washer from brake pedal pin. Removal Stoplight switch is located at brake pedal lever. Disconnect stoplight switch electrical connector. Remove hairpin clip. Slide stoplight switch, vacuum booster input rod, nylon washer and bushing away from brake pedal. Remove washer. Ensure Slide stoplight switch wiring up or down harness to remove. has sufficient length to allow for full travel with stoplight switch during full stroke of brake pedal. Reroute or repair as necessary. DO NOT substitute any retaining clip for those supplied by manufacturer. Installation Position stoplight switch with U-shaped side nearest brake pedal and directly over/under pin. Slide stoplight switch up and down, positioning vacuum booster input rod and bushing between side plates. Push stoplight switch and input rod assembly firmly toward brake pedal arm. Install washer to hairpin and install pin to secure stoplight switch assembly. Reconnect stoplight switch electrical connector. Check stoplight switch for proper operation. CLUTCH SWITCH Removal & Installation Clutch switch is located at clutch pedal lever. Disconnect clutch switch electrical connector. Pull clip downward to separate clip from tab on clutch switch. Rotate clutch switch to expose retainer. Squeeze tabs on retainer and slide retainer rearward. Separate retainer from clutch switch. Remove clutch switch. To install, reverse removal procedure. Check clutch for proper operation.
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