stiff clutch pedal cause and cure ? ( T5 )

bluestripes · 29-03-2014, 10:54 PM

General Tech Question

In regards to the t5 transmission, what causes the AU ford squeaky, stiff clutch pedal and what, if any are the possible solutions ?

Is the Mal Woods hydraulic clutch upgrade and answer to this problem or..?

BAckground information. Prior to t5 reconditioning, the clutch pedal was stiff and squeaky, than after the t5 reconditioning and the installing of a new bearing and clutch fork, the clutch shifter as smooth and soft as silk. Now some 2 months later ... the dreaded stiffness has returned and its a major pain !!

LeadFoot81 · 30-03-2014, 08:39 AM

Quote:

Originally Posted by bluestripes

General Tech Question

In regards to the t5 transmission, what causes the AU ford squeaky, stiff clutch pedal and what, if any are the possible solutions ?

Is the Mal Woods hydraulic clutch upgrade and answer to this problem or..?

BAckground information. Prior to t5 reconditioning, the clutch pedal was stiff and squeaky, than after the t5 reconditioning and the installing of a new bearing and clutch fork, the clutch shifter as smooth and soft as silk. Now some 2 months later ... the dreaded stiffness has returned and its a major pain !!

Have you tried adjusting it at the firewall? I've found backing it off and tightening again helps.

bluestripes · 30-03-2014, 08:57 AM

thanks bigfoot81 ... i will give the cable suggestion a go !!

Ford Falcon XR6 · 30-03-2014, 02:51 PM

Did you put a good lot of high temp grease on the input shaft ?? I've found in the past the shaft that the release bearing slides on gets sticky and gumed up due to lack of grease. This can cause a stiff and heavy pedal. Another suggestion is to remove the clutch cable and see if its stiff.

bluestripes · 30-03-2014, 02:59 PM

I spoke to ford spares awhile back and he reckoned unless the cable is snPped than its pretty much fine. And the fact that it was stiff prior to t5 refurb ... Than smooth and now stiff makes me think the cable is ok.

Maybe it that offer stuff you talked about. Dropping the t5 is a pain !!
F' en car ... Give me the ***** sometimes :(

fleckofly · 03-04-2014, 01:45 AM

I had a stiff clutch pedal that wouldn't let me change gears at idle i thought it was the gearbox but while getting a diagnosis my mechanic told me that inside the clutch cable sheath the actual cable has a plastic coating on it and over time the cable rubs through that plastic coating and then the plastic jams up inside the sheath making the clutch stiff. so try replacing the clutch cable... wouldn't hurt to try. i needed a new clutch at the time so when i replaced the clutch i got the clutch cable done too. worked for me no problems since.

bluestripes · 03-04-2014, 07:44 AM

Quote:

Originally Posted by fleckofly

I had a stiff clutch pedal that wouldn't let me change gears at idle i thought it was the gearbox but while getting a diagnosis my mechanic told me that inside the clutch cable sheath the actual cable has a plastic coating on it and over time the cable rubs through that plastic coating and then the plastic jams up inside the sheath making the clutch stiff. so try replacing the clutch cable... wouldn't hurt to try. i needed a new clutch at the time so when i replaced the clutch i got the clutch cable done too. worked for me no problems since.

Thanks and that makes sense. I need to change the cable. Just been caught up on another project though will post results once changed... And hopefully that's the problem

DW260 · 04-04-2014, 06:24 PM

I had a very similar issue with my old AUII ute.

The nose-cone as Ford call them, or the front retainer as gearbox specialists call them is very, and I mean very, temperamental with the grease that's used on them. It needs to be lubed up with copper grease. I wouldn't use anything else.

The same issue frustrated me... I dropped the gearbox one night, hit it 1200 grit sandpaper and applied the copper grease. It worked a treat. Never had a problem again.

If you need to replace the nose cone, ford will want close to $500 for it, but I was quoted independently $125 from a gearbox specialist for the same part.

DW260 · 04-04-2014, 06:26 PM

Oh yeah, I hasten to add, the problem happened a week after the clutch was replaced by the Mazda dealer I purchase the car from.

It was fine for the first bit of driving, but once the car warmed up it was terrible.

Bourbon Ute · 04-04-2014, 07:54 PM

+3 for the cable. Did mine not long after I bought my ute.
I tried WD40 and silicone spray down the sheath, it helped, but a new cable was much better.
Just over a year on, mine gets notchy when the motor warms up to!

superroo · 04-04-2014, 10:25 PM

I consider the cable to be a general service item.
Once I have to adjust firewall bolt more than once due to hard to shift, the cable gets changed.

As for the squeak i had which was between the brake booster and the fire wall, but only showed when using the clutch.
Bit of wd-40 on there fixed it.

Cheers