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Clutch fork modification. 

 

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 Post subject: Clutch fork modification.
Posted: Tue Nov 18, 2014 3:39 pm 
Oompa Loompa
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Age: 23

Posts: 25

Joined: 9th Nov 2014

Ride: 1996 XH Longreach

Location: Yarra Valley
VIC, Australia

Hey all,

So yesterday I was heading into trade school early morning, I pulled up to a set of lights, clutched in to take off and *snap*! Clutch clable broke, front row on a highway. Was not awesome.
Vehicle is a '96 XH Falcon Ute, T5.
Worst part was the cable being quite literally a month old.
So I stuck my head under once it was pushed to he side and yes, it had snapped right down at the bellhousing/shiftfork again.
So I pulled it all apart, took it off to repco and got a warranty part after a bit of mucking around. The guy on the other end of the phone mentioned "grinding the shift fork back and greasing it down at the connection, so the cable can't rub through."
Is this common practice? Are there any other modifications that can be made? Example; fitting some rubber so the cuble can't rub metal on metal?
I used a small file, smoothed it as best I could and put a ton of grease on it.
Any more I can do? Don't wanna replace cables every few months.

Regards,
Brutus
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 Post subject: Re: Clutch fork modification.
Posted: Tue Nov 18, 2014 6:11 pm 
Getting Side Ways
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Age: 34

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Joined: 27th Dec 2011

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Ride: ef falcon futura

Power: 154 rwkw

Location: Koo Wee Rup
VIC, Australia

your fork is more than likely slightly bent, or the rubber in the insulator is cactus.. get one of these http://www.ebay.com.au/itm/Ford-Falcon- ... 3a97b3a659 and you should never have to replace it again

 

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 Post subject: Re: Clutch fork modification.
Posted: Tue Nov 18, 2014 6:58 pm 
Technical Contributor
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Ride: ED Falcon

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NSW, Australia

^^^ I have one of those... My fork was pulled sideways and dodgy looking... Never rubbed through a cable but... Depends what yours looks like...

Cheers,
Tim

 

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 Post subject: Re: Clutch fork modification.
Posted: Tue Nov 18, 2014 7:08 pm 
Oompa Loompa
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Age: 23

Posts: 25

Joined: 9th Nov 2014

Ride: 1996 XH Longreach

Location: Yarra Valley
VIC, Australia

Thanks for that a lot guys.
I don't think there's any rubber on the end of the fork what-so-ever.
I'll see about ordering one tonight.

Regards,
Brutus.
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 Post subject: Re: Clutch fork modification.
Posted: Tue Nov 18, 2014 7:12 pm 
Getting Side Ways
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Age: 34

Posts: 1110

Joined: 27th Dec 2011

Gallery: 6 images

Ride: ef falcon futura

Power: 154 rwkw

Location: Koo Wee Rup
VIC, Australia

The rubber isnt on the fork. Its in the cylinder looking thing behind it holding the fork in place

 

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ef futura, pacemakers, 2.5inch catback, k&n panel filter and 3.45 lsd. extractors/cat, ticky head, custom cam grind, t5. now onto cosmetics.

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 Post subject: Re: Clutch fork modification.
Posted: Tue Nov 18, 2014 8:25 pm 
Getting Side Ways
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Joined: 18th Dec 2006

Ride: 93 ED sedan

Power: 161 rwkw

Location: Rockhampton
QLD, Australia

I re-routed my cable so it has a smoother path....looks untidy, but it works

 

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 Post subject: Re: Clutch fork modification.
Posted: Wed Nov 19, 2014 6:50 am 
Oompa Loompa
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Age: 23

Posts: 25

Joined: 9th Nov 2014

Ride: 1996 XH Longreach

Location: Yarra Valley
VIC, Australia

cjh wrote:
I re-routed my cable so it has a smoother path....looks untidy, but it works


Hey man,
Any chance you could post some photos of how your cable is run?
Tidiness isn't such of a concern, more so the practicallity.

Regards,
Brutus.
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 Post subject: Re: Clutch fork modification.
Posted: Wed Nov 19, 2014 6:52 am 
Oompa Loompa
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Age: 23

Posts: 25

Joined: 9th Nov 2014

Ride: 1996 XH Longreach

Location: Yarra Valley
VIC, Australia

ranga83 wrote:
The rubber isnt on the fork. Its in the cylinder looking thing behind it holding the fork in place


Hey,
Thanks for the reply.
Would you happen to have a photo of the rubber youmre talking about?
I don't remember seeing any rubber when I was under there.

Regards,
Brutus.
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 Post subject: Re: Clutch fork modification.
Posted: Wed Nov 19, 2014 9:13 am 
Getting Side Ways
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Age: 49

Posts: 6467

Joined: 18th Dec 2006

Ride: 93 ED sedan

Power: 161 rwkw

Location: Rockhampton
QLD, Australia

Brutus wrote:
cjh wrote:
I re-routed my cable so it has a smoother path....looks untidy, but it works


Hey man,
Any chance you could post some photos of how your cable is run?
Tidiness isn't such of a concern, more so the practicallity.

Regards,
Brutus.


My car is an ED.....and the hose clamp....it gives you about 2-3mm of cable travel for free....it stops the rubber cushion from squashing so much when the clutch pedal is engaged.

 

 

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 Post subject: Re: Clutch fork modification.
Posted: Wed Nov 19, 2014 12:13 pm 
Oompa Loompa
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Age: 23

Posts: 25

Joined: 9th Nov 2014

Ride: 1996 XH Longreach

Location: Yarra Valley
VIC, Australia

cjh wrote:
Brutus wrote:
cjh wrote:
I re-routed my cable so it has a smoother path....looks untidy, but it works


Hey man,
Any chance you could post some photos of how your cable is run?
Tidiness isn't such of a concern, more so the practicallity.

Regards,
Brutus.


My car is an ED.....and the hose clamp....it gives you about 2-3mm of cable travel for free....it stops the rubber cushion from squashing so much when the clutch pedal is engaged.


Hey man, thanks for that.
I believe my clutch cable is run pretty similar. Lacking that bracket off the bellhousing though. Possibly some of my issue?
I'll try using that hose clamp idea too.
I think I may have it slightly differently positioned (the cable) because I am negotiating an AU sump woth a modified EB K-frame.
Anyway, I'll stick my head under again andhave a look what I can do.

Regards,
Brutus.
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 Post subject: Re: Clutch fork modification.
Posted: Wed Nov 19, 2014 1:27 pm 
Technical Contributor
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Ride: 96 XH/97 EL

Location: South Coast
NSW, Australia

Brutus wrote:
I believe my clutch cable is run pretty similar. Lacking that bracket off the bellhousing though. Possibly some of my issue?

It's a good idea to have that bracket or similar - the inner cable has a straight run, and is central through the bellhousing hole.

 

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96 XH Longreach 'S': LPG, Alarm, 3.23:1 LSD, Cruise, Trip Comp, ABS, Power Windows, Mid Series Dome Lt, Climate Ctrl
97 EL Futura S/W: LPG, Alarm, LED int Lts, Trip Comp, F/Lane Dome Lt, Climate Ctrl, T5 Conversion

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 Post subject: Re: Clutch fork modification.
Posted: Wed Nov 19, 2014 2:08 pm 
Oompa Loompa
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Age: 23

Posts: 25

Joined: 9th Nov 2014

Ride: 1996 XH Longreach

Location: Yarra Valley
VIC, Australia

snap0964 wrote:
Brutus wrote:
I believe my clutch cable is run pretty similar. Lacking that bracket off the bellhousing though. Possibly some of my issue?

It's a good idea to have that bracket or similar - the inner cable has a straight run, and is central through the bellhousing hole.


Hey there,
I better get on to finding a bracket then.
Maybe there's all my troubles.
I'll have a look through my other conversion kit.

Regards,
Brutus.
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