Reliant Kitten Estate, Руководство по ремонту

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Page 60
5.
Release the locking springs and remove the thrust pad from
the operating fork.
6. Inspect the thrust pad for wear and renew if the bearing
face has worn below a depth of 1.58 mm (0.060 in) or shows any signs
of scoring or distortion.
To replace
1. Refit the thrust pad into the operating fork and secure with
new lock springs.
2. Insert the clutch lever shaft into the gearbox bell housing
and fit the operating fork.
3. Secure the clutch lever shaft to the gearbox bell housing
with a plain washer and new locking washers.
4. Align the retaining pin holes of the operating fork with
those in the clutch lever shaft and secure the operating fork in
position with new mills retaining pins, tapping firmly home with a
3.175 mm (0.125 in ) diameter drift.
5. Replace gearbox (see Section G )
Operation 4 The pedal assembly, removal and
re-assembly
To remove ( Figure 4)
1. Remove split pin. withdraw clevis pin and washer and
disconnect the clutch cable clevis from the clutch pedal lever.
2. Unhook the accelerator cable and nipple from the lugs on
the pedal stem and release the plastic fastener on the outer cable
from the pedal mounting bracket. Withdraw the cable.
3. From within the engine compartment, prise out the
blanking grommet situated over the master cylinder push rod clevis to
gain access to the clevis pin securing the push rod clevis to the brake
pedal. Remove the split pin and washer.
4. From within the foot well, withdraw the clevis pin and
disconnect the clevis from the brake pedal.
5. Disconnect the stop light switch wires after disconnecting
the battery.
6. Remove two nuts, lock washers and plain washers and two
bolts, lock washers and plain washers securing the pedal assembly and
the brake master cylinder to the body.
7. Carefully withdraw the pedal assembly forwards in the foot
well to clear the two weld bolts on the pedal mounting bracket.
Disengage the master cylinder from the stud on the bracket.
8. remove the pedal assembly from the foot well,
manoeuvring it past the low link of the steering column.
To dismantle
1. release the brake pedal return spring tension by unhooking
the spring from the pedal lever.
2. Remove the split pin from the brake pedal end of pivot
shaft and drive out the shaft from the bracket side members,
withdrawing the brake and clutch pedals as the shaft is removed.
3. Rotate the accelerator pedal shaft nylon pivot bushes so
that they line up with the square apertures in the bracket side
members.
4. Prise out the pivot bushes and remove the accelerator
pedal.
5. Two metal bushes are pressed into both clutch and brake
pedals. Inspect for wear and if necessary, remove with a suitable drift.
6. Replace the pedal rubbers if worn.
7. Unscrew two lock nuts securing the brake stop light switch
to the mounting bracket and remove the switch.
Operation 5 Pedal assembly - re-assemble
and replacement
To re-assemble
1. Refit the brake light switch with a lock nut on either side of
the mounting bracket.
2. Locate the accelerator pedal pivot shaft in the square
apertures in the mounting bracket side member. Fit the nylon pivot
bushes and rotate them to secure the pedal in to position.
3. Locate the return spring on the brake pedal right-hand bush
boss.
4. Position the brake and clutch pedals between the side
members of the mounting bracket and insert the pivot shaft, ensuring
the split pin hole in the shaft is adjacent to the brake pedal and
bracket.
5. Insert new split pin to the shaft.
6. Locate the brake pedal return spring over the mounting
bracket and pedal stem.
To replace pedal assembly
1. Manoeuvre the pedal assembly to clear the steering column
lower linkage and position against the pedal mounting face in the toe
box. Locate the studs on the bracket through the holes in the body
and from within the engine compartment position the master cylinder
on the stud and secure the assembly with two bolts, plain washers
and lock washers.
2.
from inside the foot well align the master cylinder push rod
clevis with the hole in the brake pedal and insert the clevis pin.
3. re-connect the brake light switch leads.
4. From within the engine compartment, through the access
aperture, refit the clevis pin washer and insert a new split pin. Refit
the grommet to the access aperture.
5. Locate the accelerator cable and nipple in the lug on the
pedal stem and reconnect the plastic fastener on the outer cable to
the mounting bracket.
6. Relocate the clutch pedal clevis to the clutch pedal and fit
the clevis pin and washer. Secure using a new split pin.
7. Adjust the clutch cable at the adjuster on the clutch
operating arm (see Operation 1 ).
8. Reconnect the battery and adjust the stop light switch.
Operation 6 Clutch cable removal and replacement
To remove
1. From under the vehicle pull back the clutch operating lever
to release the adjuster nut from the trunnion. Unscrew the adjuster
nut and withdraw the cable from the trunnion located in the
operating lever.
2. From inside the foot well, remove the split pin, washer and
clevis pin and disconnect the clevis from the clutch pedal lever.
3. From underneath the vehicle, using a 5.56 mm (7/32 in)
diameter drill bit, remove the heads from the two rivets securing the
clutch cable abutment bracket to the underside of the foot well.
4. Tap out the rivets and withdraw the cable complete with
abutment bracket, from the vehicle.
Note: The abutment bracket is press fitted to the cable during
manufacture and should not be removed.
To replace
1. When fitting a new cable assembly, which includes the
abutment bracket, two methods of securing the bracket to the foot
well can be adopted
(a)
Riveting the bracket to the foot well as in production or,