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Clutch Pedal Bushing Replacement
 
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Pelican Technical Article:

Clutch Pedal Bushing Replacement

Nick Czerula

Time:

1.5 hours

Tab:

$50

Talent:

****

Tools:

Phillips & flat-head screwdriver, 10mm socket set, diagonal pliers

Applicable Models:

BMW E46 3-Series (1999-06)

Parts Required:

Clutch pedal bushings

Hot Tip:

Be careful not to damage clutch master when replacing bushing.

Performance Gain:

Repair faulty clutch pedal bushings

Complementary Modification:

Replace clutch switch and bushings at same time

The pedal cluster in BMW E46 models with the manual transmission consists of a sturdy bracket suspended below the steering column. The brake and clutch pedals swivel on bushings on shafts on the pedal cluster bracket; the brake light switch, clutch switch and clutch master cylinder are mounted to the bracket. 

The clutch pedal bushings work as a friction surface for the clutch pedal and the mounting pin surface. There are two plastic clutch pedal bushings; both have the same part number. The bushings wear out over time creating free-play in the clutch pedal and reducing the feel and performance. It can feel as if your clutch has slack or poor engagement when the bushings are worn. If you feel that they are, grab the clutch pedal and move it side to side. It should lack free-play and lateral movement. If there is excessive movement, replace the clutch pedal bushings. 

To gain access to the cluster, you need to remove the trim panel underneath the steering column. 

To avoid marring the trim if you need to pry anything, work with a plastic prying tool or wrap a screwdriver tip with masking tape before prying out the trim panels, switches or electrical accessories.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches. 

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you are working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Do not work on your vehicle if you feel the task is beyond your ability. 

Vehicle models change and evolve, as they grow older, so the vehicle shown in our illustrations may vary slightly from yours. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

Working at trim panel above pedal cluster, remove three Phillips-head screws (green arrows).
Figure 1

Working at trim panel above pedal cluster, remove three Phillips-head screws (green arrows).

Using a trim panel tool, remove plastic rivet from trim panel (green arrow).
Figure 2

Using a trim panel tool, remove plastic rivet from trim panel (green arrow).

Working at back of trim panel behind brake pedal, unlock trim clip by rotating 90° counterclockwise (green arrow).
Figure 3

Working at back of trim panel behind brake pedal, unlock trim clip by rotating 90° counterclockwise (green arrow).

Lower trim panel, then remove OBD II connector by sliding locking tab and pulling out of trim panel (green arrow).
Figure 4

Lower trim panel, then remove OBD II connector by sliding locking tab and pulling out of trim panel (green arrow). Then disconnect footwell light electrical connector (purple arrow).

Working at clutch pedal assembly, disconnect clutch pedal return spring using diagonal pliers (green arrow).
Figure 5

Working at clutch pedal assembly, disconnect clutch pedal return spring using diagonal pliers (green arrow). Grab spring and slide out of hole in clutch pedal.

When removing clutch pedal return spring, be sure not to lose rubber insulator (green arrow).
Figure 6

When removing clutch pedal return spring, be sure not to lose rubber insulator (green arrow).

Working at clutch master cylinder (green arrow), remove two fasteners.
Figure 7

Working at clutch master cylinder (green arrow), remove two fasteners. Shown in next photo.

Working at clutch master cylinder (green arrow), remove two 10mm fasteners.
Figure 8

Working at clutch master cylinder (green arrow), remove two 10mm fasteners. Viewed from backside. Electrical connector remains connected.

Using a flat-head screwdriver, release clip and remove from clutch pedal shaft (green arrow).
Figure 9

Using a flat-head screwdriver, release clip and remove from clutch pedal shaft (green arrow).

Next, remove clutch pedal from vehicle by sliding off shaft.
Figure 10

Next, remove clutch pedal from vehicle by sliding off shaft. Be gentle and careful not to damage connections at clutch master cylinder. Remove clutch pedal bushings from clutch pedal and replace with new.

Slide inner bushing on first, then slide pedal back onto shaft (green arrow).
Figure 11

Slide inner bushing on first, then slide pedal back onto shaft (green arrow).

Slide outer bushing on once pedal is on shaft (green arrow).
Figure 12

Slide outer bushing on once pedal is on shaft (green arrow).

Be sure clip is properly installed as shown inPicture (green arrow).
Figure 13

Be sure clip is properly installed as shown inPicture (green arrow). Install and tighten clutch master cylinder fasteners. Install clutch pedal spring and check clutch pedal operation.

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Page last updated: Sat 12/3/2016 02:21:49 AM