DB9 Top Gear Track
AO Silver Member
Join Date: Jan 2007
Location: United Kingdom
County: East Sussex
Amen to this thread.
Although not too clear from the images and descriptions above, the pin (the bit that protudes from the switch and meets with the plate on the clutch pedal) has a series of grooved rings, rather like the barrel of a dart. The distance the pin protrudes is determined by a circlip within the switch.
The idea is to position the circlip so that the pin protrudes to its maximum length, then (when refitting the switch) hold the clutch pedal down, fit the switch and when you release the clutch pedal it self-adjusts the pin.
Seems that problems could happen if your foot has ever slipped off the clutch and forced the pin too far in, or if you've ever removed the clutch pedal from the linkage the pedal is now free to travel higher, so would also cause the pin to be pushed further in.
As mentioned there's no need to take the switch apart to do all this, the pin can be pulled out with long-nose pliers, I was reluctant to do this as the pin seemed to operating normally (just too short) so I feared I might damage the switch. Don't worry, you can safely pull the pin out.
Of course glueing coins to the plate that presses on the pin would also work, but not a very elegant solution.
All the best
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