Finally broke the clutch cable

[Andy911sc]

Well, my mechanic warned me that it was stretched and old. The clutch cable finally snapped. I was trying to baby it. At least it didn't happen in traffic.

So I'm compiling a list a while I am in there parts.

1. Clutch Cable
2. Omega spring
3. Positioning lever spring
4. All new springs and bushings in the pedal cluster

Anything else I should look at or think about?

[strikee]

Transmission mounts?

[Andy911sc]

good idea, but my mounts are still in really decent shape

[redstrosekNic]

Go with the bronzies for the pedal cluster!

After I did my cable and pedal cluster rebuild in my 911, the clutch feels fantastic. I have yet to drive it, but the feel of the pedal is so smooth. No need to replace the springs in the pedal cluster if they are decent shape (they are a bit pricey). They are big and tough springs.

Do some rust treatment under the pedals while you have them out. (RWebb advised me to do this)

Make sure your floorboard and rubber clutch pedal stop are in good shape. I'm pulling the wood back out this weekend to glue where it is starting to separate a bit, and to give it a coat of paint...

[nettles503]

Check the clutch actuator arm while you're rebuilding the pedal cluster.

Pedal Cluster Surprise!

[pete3799]

Soak the bolts good with PB Blaster ahead of time.
I broke one (inside on the floor) getting my pedal assembly out.

[Andy911sc]

Originally Posted by redstrosekNic

Go with the bronzies for the pedal cluster!

After I did my cable and pedal cluster rebuild in my 911, the clutch feels fantastic. I have yet to drive it, but the feel of the pedal is so smooth. No need to replace the springs in the pedal cluster if they are decent shape (they are a bit pricey). They are big and tough springs.

Do some rust treatment under the pedals while you have them out. (RWebb advised me to do this)

Make sure your floorboard and rubber clutch pedal stop are in good shape. I'm pulling the wood back out this weekend to glue where it is starting to separate a bit, and to give it a coat of paint...

Definitely getting the bronze bushing rebuild kit. I will assess the springs when I have it out. I know I had a mouse nest in the pedal cluster from when the car was sitting for 16 years, so I am interested in what the inspection will show me when I have it apart. I do have the rubber pedal stop already because I was anticipating this. Good idea on addressing the wood floor board (gluing and painting).

Any issues with sand blasting all the black pedal components and respraying with a black primer?

I am also replacing the speed sending unit while I am down there. Went out on me a few months back. I have been reading 5 - 10 mph slower on the gauge then what I am actually doing. Thankfully I have a smart phone with a gps speedo app that is surprisingly really accurate.

[Andy911sc]

Originally Posted by pete3799

Soak the bolts good with PB Blaster ahead of time.
I broke one (inside on the floor) getting my pedal assembly out.

Thanks for the reminder pete. With the mouse nest that was down there, I am sure those nuts and bolts aren't looking too healthy.

[Andy911sc]

Originally Posted by nettles503

Check the clutch actuator arm while you're rebuilding the pedal cluster.

Pedal Cluster Surprise!

Thanks for pointing this out. I will have to take my time and inspect everything carfully. Heck for all I know this could have been the part that gave out on me. Regardless of which part gave out, I am going to rebuild and rework the whole system.

[Andy911sc]

As always, I will take pictures and post them all for people to look at. We all know threads are pointless without pictures.

[Andy911sc]

Can't wait to dig into this project

[redstrosekNic]

Originally Posted by Andy911sc

Definitely getting the bronze bushing rebuild kit. I will assess the springs when I have it out. I know I had a mouse nest in the pedal cluster from when the car was sitting for 16 years, so I am interested in what the inspection will show me when I have it apart. I do have the rubber pedal stop already because I was anticipating this. Good idea on addressing the wood floor board (gluing and painting).

Any issues with sand blasting all the black pedal components and respraying with a black primer?

I am also replacing the speed sending unit while I am down there. Went out on me a few months back. I have been reading 5 - 10 mph slower on the gauge then what I am actually doing. Thankfully I have a smart phone with a gps speedo app that is surprisingly really accurate.

I used some rust converter on the floor of my car under the pedals, and some brush-on Rustoleum paint for the cluster itself. I did not want to mess up any bushing contact surfaces while painting (hence the brush, not a spray can). I'll upload some pics of the repainted pedal cluster later tonight...

You'll be glad you did all of this work when you see and feel the results!

[Jdub]

I performed the entire process from rebuilding the pedal cluster right out to replacing the cable and omega spring. The difference in pedal feel was amazing - you will be very happy you did this.

Hopefully you have not ovalled the clutch pedal shaft "ear" as per the post link above. Also, search on Peter Zimmerman's advice to me about using plastic instead of the brass I ended up using. Otherwise, a great project with very rewarding results!

[Andy911sc]

Originally Posted by Jdub

I performed the entire process from rebuilding the pedal cluster right out to replacing the cable and omega spring. The difference in pedal feel was amazing - you will be very happy you did this.

Hopefully you have not ovalled the clutch pedal shaft "ear" as per the post link above. Also, search on Peter Zimmerman's advice to me about using plastic instead of the brass I ended up using. Otherwise, a great project with very rewarding results!

do you have a quick link to where he gave the advice?

[redstrosekNic]

Originally Posted by Andy911sc

do you have a quick link to where he gave the advice?

If it is the same advice I am thinking of, it is to warn you of a failing MC. (The brake fluid destroys the plastic bushings, and lets you know of a problem. I stick with checking the fluid level.

[Jdub]

Andy - Advanced Search (Plastic Bushing + Peter Zimmermann) is your friend:

Clutch cable issue - 1982 911SC

[redstrosekNic]

Some pics...







For brush-on paint, it came out fairly well.

[Andy911sc]

Originally Posted by redstrosekNic

Some pics...







For brush-on paint, it came out fairly well.

That looks really good. I always pay attention to my fluid levels and other signs when driving. With that said, Is the feel noticeably better with bronze bushings or not really much different. As the son of a tool maker I tend to swing on the side of using a soft metal as a bushing over plastic. A well maintained machine or component will last many, many years.

[86911tlcab]

the bushings definitely feel better and wont bind or get brittle and break like the plastic ones.

taking it apart and replacing the bushings is pretty easy...

[redstrosekNic]

Originally Posted by Andy911sc

That looks really good. I always pay attention to my fluid levels and other signs when driving. With that said, Is the feel noticeably better with bronze bushings or not really much different. As the son of a tool maker I tend to swing on the side of using a soft metal as a bushing over plastic. A well maintained machine or component will last many, many years.

Thanks

My car had bronze bushings already installed, however they were quite old and lacked lubrication. The bronze bushing for the clutch arm where the clevis pin goes through was almost gone. With all new bronze bushings and some spray white lithium grease, I can't imagine a better pedal feel.