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Old 10-03-2019, 02:53 PM   #2
Citroënbender
DIY Tragic
 
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Join Date: Apr 2018
Location: Sydney, more than not. I hate it.
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Default Re: Snapped Clutch Pedal Cable Brak

The bad news is, it's stuffed.

The good news is, it's not my car.

Your firewall has failed, the cable bushing sleeve is loose; this has misaligned, the pedal is cracking its pivot off the pedal box. Plus there's the failed cage you show first.

Why does it happen? Galling on the input bearing retainer (aluminium) is a big contributor. I believe there's an aftermarket Ford Motorsport one with steel tube, which can be made to fit.

At workshop rates, there's probably $1K-ish in an honest repair if the clutch still has life in it.

New cage and bushes can be got from Fleabay, Jefferson Ford usually have them listed. Pedal box has to come out, have the pivot refixed and properly stiffened (5mm plate and TIG welds are good). While the box is out you need to weld or bond a stiffener plate to the firewall, ideally outside. I re-used the bushing sleeve tube carefully brazed into my home-made stiffener as it was already 9/10 loose, and the stiffener I then bonded with industrial urethane - two tek screws held it while the adhesive cured.
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