Gather the necessary tools and parts:
1. Replacement clutch cable
2. Open-end wrench set
3. Pliers
4. Phillips head screwdriver
5. Flashlight
6. Safety glasses
7. Wheel chocks
1. Park your MR2 on a flat surface and engage the parking brake. Chock the wheels to prevent the car from rolling.
2. Locate the clutch cable. It runs from the clutch pedal inside the car to the clutch release lever on the transmission. The easiest way to access it is by looking underneath the car. You may need to remove the undercarriage cover to gain better visibility.
3. Disconnect the clutch cable from the clutch pedal. Inside the car, look for the point where the clutch cable connects to the clutch pedal. There will be a clevis pin or a retaining clip holding the cable in place. Use pliers or a screwdriver to remove the pin or clip. Then, disconnect the cable from the pedal by pulling it towards the front of the car.
4. Disconnect the clutch cable from the clutch release lever. Go back under the car and locate the clutch release lever on the transmission. The clutch cable will be connected to the lever with a bracket or a clevis pin. Remove the pin or loosen the bolts holding the bracket in place, and then disconnect the cable from the lever.
5. Remove the old clutch cable. Once both ends of the cable are disconnected, you can remove the old clutch cable from the car. Pull it out from underneath the car.
6. Install the new clutch cable. Feed the new clutch cable through the same path as the old cable, ensuring it doesn’t get kinked or obstructed. First, connect it to the clutch release lever and then to the clutch pedal. Secure both ends with the clevis pins or brackets that you removed earlier.
7. Adjust the clutch cable. Proper clutch pedal free play is essential for smooth gear shifting. Referring to your MR2’s service manual, adjust the free play to the specified value—usually around 1/4 to 1/2 inch (5 to 12 mm) at the top of the pedal travel.
8. Test the new clutch cable. Start the engine and depress the clutch pedal several times. Make sure it feels smooth and engages the clutch properly. Take the car for a test drive and verify that all gears engage smoothly without any slipping or grinding noises.
Remember to consult your MR2’s specific repair manual for detailed instructions and specifications related to the clutch cable replacement procedure. Safety precautions should always be taken when working underneath the vehicle.
