clutch cable and clevis

johnnyboy42 · 05-21-2004, 08:45 PM

Hello all:

I have a 78 SC Targa. When pulling into my driveway after work, as I depressed the clutch, the pedal went straight to the floor and stayed there. I've experienced broken clutch cables before, and this is what they feel like. So, using Wayne's book (101 Projects, Project 9), I start disassembling.

I think I confirmed the broken cable, too, as I can pull the cable from the front of the tube with no resistance whatsoever. I'm down to the part where it says there is a pin of some kind holding the u-shaped clevis, but I can't see any pin. Where am I supposed to be looking?? There isn't much room on the right side of the pedal cluster, is there.

Since this is my daily driver, I'm picking up a new clutch cable locally tomorrow a.m. Any assistance would be appreciated. Thanks in advance.

johnnyboy42

P.S.: I have no confidence at all in my mechanical abilities, but my wife does. (She's the one who bought 101 Projects for me for Christmas.) So, I'm giving this the old college try. Help, please.

dean · 05-22-2004, 04:32 AM

The clutch pin clevis is in there. You can only see it or remove it with the clutch pedal on the floor.
Have fun

Zeke · 05-22-2004, 06:34 AM

By definition, a clevis pin is a pin thru something with a keeper, a circlip, cotter key, lynch pin or the like securing it. On your clutch cable, there is a pin thru the end fork, but it has a clip attached to it that runs back on the cable itsself. This is a pinch clamp around the hard cable threaded end. Flip this off and the pin will pull out to the side.

Schrup · Schrup's Garage

Johnny, welcome to the board. If you can't seem to pull the pin out after you flip up the clip, it is probable because the pin has worn through the plastic bushing & started a groove in your clutch pedal shaft . I had to break my clevis to get the pin out. I was able to clean up the end of the shaft & press in a new brass bushing. You may consider a pedal cluster rebuild while you're in there. Good Luck.

North Coast Cab · North Coast Cab's Garage

I searched and can't find a picture online. However, the pin probably doesn't look like what you think it does. It is a small rod/pin (1/2") attached at a 90d angle to a flat type piece of sheet metal which folds back and snaps onto the fork. It's possible it broke off and that has caused your problem. Look around, quarters are pretty tight in there.

John

Schrup · Schrup's Garage

Here's a pic.

johnnyboy42 · 05-22-2004, 10:38 AM

Thanks, guys. I finally figured it out this morning and got the clutch cable pulled out. I was right, it had snapped. I bought a new one locally and hurried home to install it. To my mechanically challenged mind, this actually seemed fairly easy. I got the thing in and hooked up, feeling very proud of myself.

Unfortunately, I seem to have stumbled somewhere, because my clutch pedal doesn't return to its starting place when I release it after engaging. Do I just have to readjust the cable at the rear? I went out and bought a hydraulic floor jack and jackstands just for this project. Please tell me I can lick this.

Thanks for your help.

johnnyboy42

aka johnjr (office handle)
78 SC Targa

P.S.: The spring attached to the clutch pedal is not broken, so I don't know why the pedal won't just snap back like it's supposed to.

Jim Sims · 05-22-2004, 08:45 PM

Adjust the cable length; if that doesn't work you may have a shearing or deforming roll pin in the clutch pedal cross-shaft. Jim

Noel · 05-23-2004, 02:53 AM

I had the same problem you describe with the pedal not returning fully. It is most often due to the cable not being adjusted correctly. CHeck out this link, it will walk you through the process.

http://www.pelicanparts.com/techarticles/911_clutch_cable/911_clutch_cable.htm

johnnyboy42 · 05-23-2004, 04:57 AM

Thanks, guys. I go at it again this morning.

johnnyboy42

johnnyboy42 · 05-23-2004, 08:26 AM

Okay, now what did I do? I tried to tighten the adjusting screw on the small lever arm like the tech article says and instead of closing the clearance it actually increased it. Now, I can't get the clearance anywhere near 1.2 mm even when I tighten the screw all the way. HELP!!

Johnnyboy 42

Noel · 05-23-2004, 12:12 PM

Again. Been there. I had to manually snap the horseshoe spring back to get the position correct prior to adjusting the clutch cable. Once you do this, it should be OK. Just confirm that the horseshoe spring is against the heat exchanger. If it isn't then you need to snap it back. This will allow you to get the 25mm of travel required.

johnnyboy42 · 05-23-2004, 03:00 PM

It's COMPLETED!! Once I WD-40'd the heck out of the arms and helper spring, everything worked right. I can't believe it. I test drove her just to be sure, and by golly the job is now DONE! I've never done anything remotely like this, so I truly appreciate all of your responses and suggestions along the way.

Thanks again!

johnnyboy42

aka johnjr
78 SC Targa

Jim Sims · 05-23-2004, 03:56 PM

Next time do not use WD40 for this type of task, use an aerosol penetrating oil like "Kroil" or "PB Blaster". WD-40 is a preservative that will dry to form a sticky varnish that will gum things up. Congratulations on fixing your clutch. Cheers, Jim