Fixing Cracking Firewall

mark180227 · 30-01-2008, 01:44 PM

Hey All.

Time to get the cracked firewall fixed. I've got tsunamis coming in my car everyone time it rains and running out of adjustment on the clutch cable so its time to fix it.

Where abouts do I go to get this fixed, and can anybody recommend somebody.

cheers guys

**GasoLane** · 30-01-2008, 03:34 PM

I'd say any panel beater, how did it get cracked in the first place?

james22 · 30-01-2008, 04:37 PM

Common manual ford problem since the effin EA lol. I hate pedal boxes and firewalls.

JC · 30-01-2008, 06:58 PM

Quote:

Originally Posted by mark180227

Hey All.

Time to get the cracked firewall fixed. I've got tsunamis coming in my car everyone time it rains and running out of adjustment on the clutch cable so its time to fix it.

Where abouts do I go to get this fixed, and can anybody recommend somebody.

cheers guys

Buy some 1/4" steel plate, cut it to fit the spot you need and bolt it in.

FGII-XR6 · 30-01-2008, 07:26 PM

AFAIK ford have a kit for this

congo3sr · 30-01-2008, 08:53 PM

Quote:

Originally Posted by JC

Buy some 1/4" steel plate, cut it to fit the spot you need and bolt it in.

this bloke is joking.....I hope

:
cheers George

WindsorXR · 30-01-2008, 08:58 PM

This happened in my EL XR6. I took it to a specialist joint and they said that there are actual kits you can get to fix this.It's basically a bit of plate with hollow tube for the cable to go through and it stiffens up the firewall and stops the wall from creeking every time you use the clutch or brake.

superroo · 30-01-2008, 09:47 PM

Quote:

Originally Posted by congo3sr

this bloke is joking.....I hope

:
cheers George

Essentially, no. There also needs to be tube welded to the plate.
Here is my quick fix to the crack that i had around the tub. It's a doddy job that i will get round to eventually doing properly, using a bigger sized plate, and bolting it to the fire wall.

It works, but i'd like to have something over kill in there, so i know it won't be a problem

Cheers

kcej · 31-01-2008, 12:43 AM

Quote:

Originally Posted by james22

Common manual ford problem since the effin EA lol. I hate pedal boxes and firewalls.

Since the EA my bottom........had this prob in my very first XF I ever bought, and I'm sure that wasn't the first manual ford to have it lol

james22 · 31-01-2008, 09:02 AM

I stand corrected lol. EA gave me the shits something chronic. 2 Pedal boxes and a firewall job. What a PITA

loxxr6 · 31-01-2008, 03:42 PM

Quote:

Originally Posted by au3xr6

AFAIK ford have a kit for this

Exactly what I was told but several dealers have said to me they know nothing about it.

Be careful who you get to do the repairs. One joint wanted to pull my whole dash out to do it...

VCT_XR6_UTE · 12-02-2008, 10:54 PM

Just found out i need this job done to my ute, pedal is really hard to push and the pedal is bent all out of whack, anyone know a rough cost for this job?

philstoj · 12-02-2008, 11:16 PM

Before you go and rip the cars apart and weld plates in etc, before you do anything, find the source of the leak first!! Will save you plenty of $$$$$$$.

I have had this problem up untill recently...

I have found the leak and sealed it, cost peanuts and didnt take long to fix.

I too thought i had a cracked firewall, broken pedal box (in fact its a bent clutch pedal) so i stripped out the car, removed the wiper motor and arm assembly, got the missus to spray water in the cowl (bottom of windscreen) and found the culprit, a dodgey spot weld, a hole where a spot weld should have been, easy fix, fill it with urethane ( i had some on hand ) job done, no more leaks.

So before you go out shelling thousands to get something welded that doesnt need to or isnt broken, check it out first, and then fix it.

philstoj · 12-02-2008, 11:19 PM

Quote:

Originally Posted by VCT_XR6_UTE

Just found out i need this job done to my ute, pedal is really hard to push and the pedal is bent all out of whack, anyone know a rough cost for this job?

Change your pedal and pedal box, replace your clutch..
How the hell do you change gears?

**Mechan1k** · 12-02-2008, 11:28 PM

Quote:

Originally Posted by loxxr6

Exactly what I was told but several dealers have said to me they know nothing about it.

Be careful who you get to do the repairs. One joint wanted to pull my whole dash out to do it...

After seeing this being done ... I can safely say it is easier to get this work done on the AU compared to the EL I just witnessed.

The EL need the dash to be unbolted but not completely removed. The AU don't need the dash to be touched.

It's the only time I can safely say "Thank God I drive an auto".

LPGUTE · 22-02-2008, 08:51 PM

my firewall look like it been fix but....i have a question....dose the plate in the picture or the cable suppose to move? because mine is...

the plate look like it had not been welded.

mark180227 · 12-03-2008, 11:33 PM

can anybody suggest any places in melbourne to get the firewall welded up etc?

mark180227 · 16-03-2008, 08:07 PM

anybody?

GK · 16-03-2008, 09:24 PM

Any decent panel beater could do it. Choose one that you know and they'll be able to weld up something for you no worries.

All the best with it.

GK

loxxr6 · 31-03-2008, 03:40 PM

Quote:

Originally Posted by mark180227

anybody?

Just print the pics off in the thread and take it to any panel beater. You'll be fine.

mark180227 · 11-04-2008, 04:37 PM

Took the car to Ford the other day just to see what they thought about it. They said they would have a look at and get back to me. So i left it with them for the morning, upon returning this is what they presented me with.

Clutch Kit
Clutch Cable
Clutch Pedal Box Assembly
Flywheel Machine
Cluth fork Bush
Firewall to be Welded Both Sides
Dash Needs to be Removed
Brake Master Cylinder, Booster, Firewall Insulation and ENGINE require to be removed to Repair Firewall
Parts Cost @1209.90
Labour @ 15.5 Hours $1670.90
Welding and Reinforcement Repair $250.00
Tow Truck Transport from Panel Shop $240.00

For a Total cost of 3370.80.

found this quiet interesting.

blueoval · 11-04-2008, 04:45 PM

:

Take that list (erase the pricing) to a trusted mechanic and get another quote.

F6 R-Spec · 11-04-2008, 04:57 PM

Hi there mate, i owned a ed xr6 5 speed with headers from day one i bought it, i had traveled over 150.000 klm's in it, the current owner has done another 150.000klm's in it with not a problem with the fire wall.

why you ask?
dont skimp on replacing clutches & cables, as soon as the clutch/cable feels hard or about 60-100.000 k's get rid of it.
piece of mind.

Or what i do to customers car's is i bolt a 1/4 inch steel plate with the a cable hole, mounted on the inside to stop flex. Also get your pedal box welded as there spot welded from fomoco.

cheers mick.

Night · 16-04-2008, 10:05 PM

You would think that this is a design defect that Ford should have to fix. How come they are allowed to get away without recalling the cars for?

mark180227 · 16-04-2008, 10:27 PM

Quote:

Originally Posted by Night

You would think that this is a design defect that Ford should have to fix. How come they are allowed to get away without recalling the cars for?

thats exactly why i rang Ford and complained about it. I said the same thing, that its a design fault in the car and Ford should be responsible for fixing it. But true to reputation, customer care treat you like and dont want a bar of it. It's rediculous.

loxxr6 · 17-04-2008, 04:30 PM

Quote:

Originally Posted by mark180227

Took the car to Ford the other day just to see what they thought about it. They said they would have a look at and get back to me. So i left it with them for the morning, upon returning this is what they presented me with.

Clutch Kit
Clutch Cable
Clutch Pedal Box Assembly
Flywheel Machine
Cluth fork Bush
Firewall to be Welded Both Sides
Dash Needs to be Removed
Brake Master Cylinder, Booster, Firewall Insulation and ENGINE require to be removed to Repair Firewall
Parts Cost @1209.90
Labour @ 15.5 Hours $1670.90
Welding and Reinforcement Repair $250.00
Tow Truck Transport from Panel Shop $240.00

For a Total cost of 3370.80.

found this quiet interesting.

I'd tell them to do what a duck can't. Shove their bill up their ar$e.

What did you end up doing ?

Night · 17-04-2008, 10:03 PM

As dumb as this sounds, I would think that it could be a major defect not only because of structual reasons but because of engine fumes entering the cabin. I can't see how the goverment allows ford to get away with this as I'm sure if a cop pulled you over and saw a rubber plug missing in your firewall he would defect you for that very reason. How come ford don't have to recall their cars?

mark180227 · 17-04-2008, 11:04 PM

Quote:

Originally Posted by loxxr6

I'd tell them to do what a duck can't. Shove their bill up their ar$e.

What did you end up doing ?

got in my car and drove off.

no chance in hell of me paying that.

I know my whinging isnt going to do much, but i think Ford should be accountable for such a defect like this. It has effected so many cars on this forum, let alone any body else in the general public.