Clutch pedal (Discovery 3)

Removing

1. Remove the brake booster. For more information refer to Vacuum Brake Booster (70.50.01)

2. Remove the headlight switch. For more information refer to Headlight Switch (86.65.09)

3. Remove the decorative panel from outside the driver.

• Release the clamp.
• Remove 2 screws.
• Disconnect the electrical connector.

4. Remove the instrument panel access panel. Release 2 clips.



5. Remove the brake pedal bracket.

• Disconnect the wire harness clamp.
• Remove 4 Torx bolts.

6. Disconnect the brake light harness.

• Disconnect the electrical connector.
• Release 2 clips.

7. Remove the brake light switch.



8. Remove the spring assisted clutch pedal mechanism.

9. Remove the clutch master cylinder.

• Release the clutch master cylinder yoke pin.
• Loosen 2 nuts.

10. Remove the pedal assembly. Loosen 2 nuts.



11.

NOTE: Do not further disassemble if the part is removed only for access.

Remove the brake pedal pad.

12. Remove the clutch pedal pad.

13. Remove the pedals.

• Carefully loosen the spring tension.
• Loosen the bolt and discard the nut.

14. Remove 3 pedal bushings.

Installation

1. Install bushing.

• Clean the contact surfaces of the parts.
• Lubricate the details.

2. Install the pedals.

• Install the return spring.
• Tighten the nut and bolt with a tightening torque of 45 Nm.

3. Install the clutch pedal pad.

4. Install the brake pedal pad.

5. Install the stoplight switch.

6. Install the pedal assembly. Tighten the nuts with a tightening torque of 25 Nm.

7. Install the clutch master cylinder.

• Tighten the nuts with a tightening torque of 10 Nm.
• Install the fork pin.

8. Install the spring-loaded clutch pedal assist.

9. Attach the wiring harness.

• Fasten the clamps.
• Connect the electrical connector.

10. Install the brake pedal bracket.

• Tighten the Torx bolt with a tightening torque of 10 Nm.
• Attach the wiring harness.

11. Install the instrument panel access panel. Fasten with clips.

12. Install the decorative panel.

• Connect the electrical connector.
• Fasten the clamp.
• Tighten the screws.

13. Install the headlight switch. For more information refer to Headlight Switch (86.65.09)

14. Install the brake booster. For more information, refer to Vacuum Brake Booster.