Cracked Firewall where clutch cable enters.

[CliffM]

Has anyone experienced this particular problem? Apparently the cable tears a whole in the firewall of the AU. I talked to my mechanic today and he says anything up to a full day...

In particular I'm looking at an aftermarket replacement footbox as an option. I figure if I'm paying for a full days labour then I may as well do the job right.

[XC_Lizzard]

Its not an uncommon problem in cars with cable operated clutches, particularly if the clutch has got bit bit stiff at any time and extra effort been used to operate the pedal.

I've personally seen it (or where its been repaired/reinforced) in a JB Camira, TD Cortinas, an XF Falcon, an EF Falcon, and a Laser.

The fix is just to add some reinforcement/bracing around where the clutch cable goes through the firewall to spread the load. The time consuming part is getting reasonable access to that area of the firewall.

[ratman]

Common problem back to the X series mate. Every E series I've had has done the same. Make sure whoever does the repair welds in an extra reinforcement plate over the cracked location to brace up the firewall so u don't have the problem again - its easier (and cheaper) to change cales down the track than go thru this process for a 2nd time. Do a search as it has been covered on here many time before.

[tex]

The clutch pedal in my EF snapped off at the hinge on the firewall. The hinge didn't fail, the firewall just broke away....

It's not a small job, part of the dash had to come out of it to be welded into place

[XC_Lizzard]

Originally Posted by tex

The clutch pedal in my EF snapped off at the hinge on the firewall. The hinge didn't fail, the firewall just broke away....

It's not a small job, part of the dash had to come out of it to be welded into place

Thats strange, the clutch pedal on my EF is pivoted on the pedal box, not the firewall.

Breaking the pivot on the pedal box is a different problem from tearing the firewall where the cable goes through. While I have never removed the pedal box from an EF, I wouldn't have thought that you would need to remove any of the dash to remove the pedal box.

[CliffM]

This depends on how the break has progressed. It's not that easy to repair if there is a large break. This is what my mechanic said, once the brakes are removed you can get access to the damge. Sometimes you can fix it, other times you have to remove the pedals... this is why it can take all day.

[rob_liss_lms10]

It is a common prob, do a search and you will find heaps of answers to the same prob.. for example http://www.fordforums.com.au/showthr...acked+firewall

[CliffM]

well I fixed this problem today for nothing but a bit of time.

I removed the clutch pedal, disconnected the cable, slid it into the engine bay.

I gently hammered the cracked firewall back into place with no problem.

I had an old Jack laying around so I removed the pressed steel plate foot, drilled and elongated a hole to run the cable through. I put one screw in it and used it against the firewall.

Works wonders, best the clutch has ever been....

[CARLO5]

yeah bro happened to me had to drive home thru peak hour traffic in sydney with no f@cking clutch! lol. had to get the firewall welded up at the panel beaters. was a bloody nightmare

[ebxr82nv]

It happened in my au, tore out a 50c piece size of firewall. Took me about a day to fix. 2 pieces of 3mm plate shaped and welded together covering as big an area as posible, went to ford and got the 'official' repair piece(yes they have them, but only listed for one of the x series cars) welded that on also then drilled some holes and bolted it to the firewall.

the only problem with just plating the wall and drilling a hole in it is the cable doesnt run at the right angle.

[CliffM]

I elongated the hole so the cable finds it's own angle, the original tube is back in place and seems ok.

[fordfreak]

does anyone have a pic of a cracked firewall in an AU?