My clutch pedal!

DENKO · 11-06-2006, 03:19 PM

hi guys look my clutch pedal has ed up! it doesnt want to go all the way in and makes my gears crunch! its the bracket and bolt that have stuffed up! any clues on how to change it other then taking it to a mechanic? anyone know the prices for a new clutch pedal? any help will be fine,
cheers!

JC · 11-06-2006, 06:24 PM

Quote:

Originally Posted by S-MAN

hi guys look my clutch pedal has ed up! it doesnt want to go all the way in and makes my gears crunch! its the bracket and bolt that have stuffed up! any clues on how to change it other then taking it to a mechanic? anyone know the prices for a new clutch pedal? any help will be fine,
cheers!

It's probably not the pedal, but the bracket at the firewall that has cracked/broken - a common problem for all manual falcons since about XP. Another good reason to go auto. LOL.

XR6-VCT-2000 · 11-06-2006, 06:41 PM

Quote:

Originally Posted by JC

It's probably not the pedal, but the bracket at the firewall that has cracked/broken - a common problem for all manual falcons since about XP. Another good reason to go auto. LOL.

As JC just said .... probably the case . :(

robbo_yobbo · 11-06-2006, 06:42 PM

Mine cost me $89 from a wreckers, but I'm positive you could pick one up under half that if you look around, I just didnt have the time to wait

DENKO · 11-06-2006, 07:13 PM

thanks guys it is the bracket and also are they easy to put in?

robbo_yobbo · 11-06-2006, 07:25 PM

The manual says the dash has gotta come out but i cant see why, i recon it'll go in with a bit of fidling

shepv8 · 12-06-2006, 06:02 PM

a few guys were discussing this on a thread a few months ago and reckoned it can be done without removing the the dash.
The thread dicussed strengthening the new bracket. Might be worth a search of old threads.

blue terra · 12-06-2006, 07:56 PM

i've had it done. clutch cable pulled right through the firewall. Had ford fix it. My dash came out so they could weld 2 plates either side of the firewall for strength. was a costly op for me.

DENKO · 12-06-2006, 08:45 PM

how much exactly blue terra coz i got a quote yesterday for 300 bux fitted from VELI motors in epping!

blue terra · 12-06-2006, 08:56 PM

put a 1 in front of the 3 and u are gettin close. I didnt get a new pedal box just plates welded either side of the firewall so it wont happen again. if the pedal boxes are faulty its going to keep happening so my ford dealer strengthened up the firewall. Ford aus dont recognise it as a problem because it aint a safety matter to them. I also had the clutch burnout so that needed replacing. clutch from ford 560 same clutch from repco 340.

DENKO · 12-06-2006, 09:01 PM

far out dats alot of money so you think its better to have it welded to the firewall then getting a new one?

blue terra · 12-06-2006, 09:10 PM

Not sure mate. It's a costly excersie. me and antilooped went through it at about the same time. Thing is a mechanic told my old man falcons are really only made for auto's. cos thats what are mainly bought these days. It depends how bad it is. mine popped right through to say hello to me while drivin and couldnt get gears. its all good to buy a pedal box but its going to need strengthening at the point where the clutch comes through cos it will weaken it again and only do the same thing. Its not fun when it happens and just costs more money. And ford Aus find ways to get out of payin for their fault

sickxr · 13-06-2006, 08:17 AM

Yeah im getting a bit worried about this happening to my falcon. The clutch seems to get heavier every week. I have already replaced the clutch cable which made it ok for a month or so, but now it is just back to how it was.

XR6-VCT-2000 · 13-06-2006, 09:17 AM

Yeah it is a common problem with the manuals / not just fords, and if you don't get some extra thick steel plate welded to the firewall to support the bracket, then its almost inevitable that your gonna get a cracked firewall around the bracket in the end .

Imo if your fixing the bracket anyway, and if your planning on keeping the car another few years , it would be worth spending that bit exrta to get the support plates welded onto the firewall anyway, otherwise you'll just be repeairing it again in a few years .

DENKO · 13-06-2006, 01:05 PM

is it easy to weld to the firewall?

XR6-VCT-2000 · 13-06-2006, 01:15 PM

Quote:

Originally Posted by S-MAN

is it easy to weld to the firewall?

lol , depends if you can weld ! , you could even do it with a mig welder no worries , just be sure to disconnect BOTH the battery terminals before welding anything on ya car ;) . Another safe point is to earth the car body out on something large / metal after your done before connecting the battery again / disconnect the welder lead before earthing it out ! ( this procedure is just to make sure the is no charge/static left in the car body which could damage the ecu ) - not much chance of it though ;) . Make sure you have all fuel lines fully sealed/covered , do it in a well ventelated area , cover as much as you can under the hood co's you'll end up getting spit/slag from the welding as your welding leaving marks on everything otherwise (mig is bad for spitting crap / tig & arc aint to bad).

DENKO · 13-06-2006, 01:18 PM

so what your saying is it is possible to do a backyard job!LoL

dinga · 13-06-2006, 01:24 PM

Quote:

Originally Posted by S-MAN

is it easy to weld to the firewall?

Be carefull. If you don't know what you are doing, don't try it.

I took my ute to a "reputable" panel shop to get it done ($300). Since I got it back, I have had to replace the Smart Lock ($400 approx), computer ($400 approx), new key (you can't reporogram the smart lock with only 1 key $$$$), a couple of other electrical problems that I have deleted from the memory and now the blinkers have bitten the dust.

But the clutch is great.........

XR6-VCT-2000 · 13-06-2006, 01:25 PM

Quote:

Originally Posted by S-MAN

so what your saying is it is possible to do a backyard job!LoL

if you can at least do a half decent welding job without blowing holes everywhere , then yeah for sure . Just remember to be really carefull , almost safer to like weld it on in small bits at a time , allowing to cool in between welding ( do like 5cm weld max at a time , then let it cool ) , up to you , just to be safe though as you know metal gets extremelly hot when welding and you dont wanna go melting other stuff within the region of that area ! , last thing you want is a fire under the hood ! . If you dont trust welding some support plates on , you can even bolt them on , i have seen a firewall fixed with checker plate on both sides and drilled and bolted on all the way around , just as stong / nearlly , but definatelly strong enough for that application , alot safer than welding under the hood too if you dont trust yaself ;) . gl

DENKO · 13-06-2006, 01:36 PM

nah im not gona weld it myself
probley replace it with a new box, would a BA clutch pedal box be able to replace my pedal box giving it a hydrolic clutch ratherthen cable?

XR6-VCT-2000 · 13-06-2006, 02:06 PM

Quote:

Originally Posted by S-MAN

nah im not gona weld it myself
probley replace it with a new box, would a BA clutch pedal box be able to replace my pedal box giving it a hydrolic clutch ratherthen cable?

Im not sure weather it will fit , might do - regardless weather it does or not you can probably find some hydraulic clutch setup which could be made to fit and work. I haven't had manuals since i was young , but back then even it was possible to fit certian hydraulic clutches to a variety of cars. Someone with a manual that has upgraded from the AU to the BA/BF might be able to help you out with this one a bit more ;) .

blue terra · 13-06-2006, 06:39 PM

Quote:

Originally Posted by S-MAN

is it easy to weld to the firewall?

Problem with the firewall. Its not flat the ford technician had to kinda shape it too the firewall. for mine to pull through now it has to go through 7mm of hardened steel. Sorry to be the bearer of bad news S-MAN.

**Papa Smurf** · 13-06-2006, 08:37 PM

Quote:

Originally Posted by S-MAN

nah im not gona weld it myself
probley replace it with a new box, would a BA clutch pedal box be able to replace my pedal box giving it a hydraulic clutch rather then cable?

Only problem with that is BA's have a Throwout Bearing and slave cylinder combined, costs a fortune. Better off replacing the original box.
The Dash isn't that hard to remove, just a little time intensive. Far easier than earlier models

DENKO · 14-06-2006, 02:03 PM

Good news guys, my dad and cousin replaced my clutch pedal box by them selves with out moving the dash! my cousin took out the clutch box in about 15 minutes and then they put the new one in, it took them bout 2 hours all up!

shepv8 · 14-06-2006, 05:46 PM

good work guys.
Hey, any chance of some pics of the broken unit. Im thinking of getting a new one and strengthening it just in case, and would like to see where yours cracked

shepv8 · 14-06-2006, 05:49 PM

hey papa smurf, just out of curiosity, how long do u reckon to remove an AU dash. 1 hour , 3 hours??? Obviously u could do it a fair bit quicker than someone who has never done it before

**Papa Smurf** · 14-06-2006, 09:15 PM

About 1.5-2 hours would be a fair time factor. Just have a good memory and attention to detail. Having the RADIO code is a good idea as well