2004 Saturn ION Logo
Posted on Jun 10, 2011
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Clutch pedal has about 1/2 inch of play before engaging, from the floor. How can I adjust this?

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  • Master 3,911 Answers
  • Posted on Jun 10, 2011
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Joined: Feb 14, 2009
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There is a very small amount of adjustment on the rod which pushes in the master cylinder piston. what you are talking about however, the engagement point, is that your clutch pressure plate and disc need to be replaced. they are worn out and not releasing until maximum movement of the slave cylinder. this will not be cheap.

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Had a new clutch in chrysler voyager 2.5 td only done few thousand miles clutch bite soon as move pedal up car to get in gears have to start car in gear can feel car moving slightly

check to see if you can adjust the clutch cable and make it a little tighter. they stretch over time. The amount of play is only a 1/2 inch or so. have someone sit inside and push the clutch peddle in and out and see where it starts to move. Loosen the locking nuts and adjust thread play till the peddle engages about a inch or two from the top. Not near the floor. It is not hard to do when you look at it closely.
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The clutch is not fully disengaging. Adjust the clutch cable to obtain a 1/2 inch of free play at the top of pedal stroke. If clutch adjustment is not correct, damage to synchronizers or clutch release bearing will occur. Your clutch should begin to engage about an inch off the floor when releasing the clutch pedal.
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engaging?
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pedal up is engaged,
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Your pedal height may be adjustable by a stopper bolt at top of pedal. You would have to check the specification for your car. Most important that the pedal has about a half inch free travel before clutch begins to engage. You need that free play to ensure the release bearing (the throw-out bearing) is not touching the fingers on the pressure plate when not engaged. If it always is touching, it will be rolling around constantly and will go out prematurely.
Your new clutch will allow gear engagement sooner as the clutch pedal is released. I mean gears will engage just as pedal is lifting off from floor. You should notice that difference-the old clutch would have taken longer pedal travel from floor before releasing.
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The clutch pedal on Suzuki vitara two litre V6 1998 goes to about inch of floor before activation. Clutch does not slip just too much pedal travel. Is it possible to adjust it? ...

prev.gif next.gif Clutch ADJUSTMENTS 1997-98 Models CLUTCH PEDAL HEIGHT The clutch pedal height should not be a periodic adjustment but may be checked after components of the mechanical clutch system have been replaced. The proper clutch pedal height should be 0.2 in. (5mm) above the brake pedal height If adjustment is necessary, loosen the locknut and turn the adjusting bolt until the appropriate height is reached. Once set, keep the bolt from turning and tighten the locknut to secure the adjustment. CLUTCH PEDAL FREE-PLAY The clutch pedal free-play should be checked from time-to-time in order to assure proper clutch operation. The proper clutch free-play should be 0.6-1.1 in. (15-25mm). Fig. 1: Pedal free-play is adjusted at the joint nut (2), while keeping the outer cable nuts (3) tightened around the center cable thread portion 7924hg30.gif
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. If the free-play must be adjusted, turn the joint nut (2) located at the transmission end of the clutch cable in or out, as necessary to achieve the proper play.
  3. Once the correct pedal free-play is obtained, check the free-play on the release arm (c), it should be 0.02-0.06 in. (0.5-1.5mm).
1999-01 Models These vehicles are equipped with a hydraulic clutch system. No adjustment is necessary.
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You want to shorten the cable. Loosen the lock nut.Turn the cable adjuster clockwise to shorten the cable. This takes some skill, and knowledge to get the clutch adjusted just right. You want about 1/2 inch of free play in the pedal. All of this varies according to the wear on your clutch. You say your clutch is new, so acheving a proper adjustment should be no problem. Keep tweaking the adjustment to get it catching where you like it.
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