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Cracked firewall around Clutch cable! Help plz. 

 

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 Post subject: Cracked firewall around Clutch cable! Help plz.
Posted: Thu May 10, 2007 4:46 pm 
Tyre Shredder
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My clutch has started to loose its pressure (i have to push right down hard on the floor to get a smooth change) so anyway I take it to get a cable replaced and this is what my mechanic found. He says its common in X and E series manual falcons.

The fire wall has cracked around where the cable passes through. Apparently it happens when the cables lose greese and become tight. The cable is strong and the firewall is weak therefore resulting in this.

Ive been quoted:

$50 - $80 - Brake Master and Booster Removal
$120 - To Weld the Firewall
$97.70 - New clutch Cable (Genuine Ford Part)

Then...

$300ish if the cable is still too tight the gearbox will have to be removed.

So now the questions:

1. Do these prices seem realistic?
2. Does the gearbox have to be removed for lubricating or fitting of a clutch cable?
3. EF 7K553 A - Is this the correct part code for an EL i6 clutch cable? - The girl at ford wasnt very specific even though I was.
4. Is this a common occourance to crack the firewall?

I cant say im overly happy about this happening. I just spent the cash I had saved on a new bonnet. I will proably opt for a new clutch with the gearbox is out as i believe this is still the original clutch and at 174,000 it couldnt hurt.

 

 

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Posted: Thu May 10, 2007 6:13 pm 
Getting Side Ways
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50-80 seems pricey to remove booster/master cylinder considering its about two bolts under the dash and that gives enough clearance to weld,again 120 to weld seems expensive but every where is different for 120 i'd expect some extra bracing around the hole too.and i can see no reason why the gearbox should have to come off unless clutch is being shimmed up(sketchy job)or clutch is being replaced.
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Posted: Thu May 10, 2007 6:43 pm 
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yeah it common for the firewall to crack as both my other cars had the same problem but i just welded it where it was i didnt pull any parts out to do it

 

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Posted: Thu May 10, 2007 8:13 pm 
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pm sent
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Posted: Thu May 10, 2007 11:51 pm 
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Yeah getting around this, as im putting my manual in tomorrow, any hints to strengthen would be great.

 

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Posted: Fri May 11, 2007 1:26 am 
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common as a**holes mate. Secret is keep the clutch adjusted correctly, and replace the clutch when it gets too stiff (meaning its almost worn).
That seems pretty reasonable for repairing the firewall bearing in mind it will need to be painted etc.
We got one done at a panel shop we use at work and i cant remember what it was but they welded in an extra plate and painted it at the same time.
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Posted: Fri May 11, 2007 1:43 am 
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yeah this panel beater said to me he will make it look good so no body will think its been in an accident. To which i replied "Ill drive this thing into the ground so it dosent really matter".

The clutch itself is really fine (besides a slight shudder when taking off which indicates warped flywheel [according to steven - dave]) but i think the cable has always been stufffed. Bought a new one today anyway. It just has to hold out until pay day next week. If the peice on the firewall completly breaks im rooted though
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Posted: Fri May 11, 2007 10:12 pm 
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it should be okay. Just be gentle with it.
You'll most probably find at some point somebody has driven it with an incorrectly adjusted clutch for a while.

Stevens on the money with the warped flywheel, but regardless you should always machine the flywheel when u replace the clutch anyway.
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Posted: Fri May 11, 2007 10:26 pm 
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this happend to my ED XR i fixed it buy using two XD Clutch cable mounts i drilled out the firewall to match the XD mount, i modified one of the XD mounts so that it would sandwitch the firewall, i will take some pics and post them tomorrow if any one is interected it was quite easy and quick to repair and with no welding needed, tools i used was a drill,10mm drill bit, die grinder and angle grinder..

 

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Posted: Fri May 11, 2007 10:40 pm 
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I understand you can still purchase a premade fabricated plate from Ford.
And any backyarder can install it.

 

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Posted: Fri May 11, 2007 11:28 pm 
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@dave - Yeah if the gear box ever comes out ill have the flywheel machined. The Clutch in it now is fine though. Plenty of hold (hard snaps on 2nd) so the warped flywheel is an issue ill deal with for the time being and just pray and hope s**t dosent hit the fan.

@sexyr6 - Yes please dude, some pics would be sweet. Any help at the moment is appreciated as im absolutly strapped for cash (everything seems to just come at once)
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Posted: Sat May 12, 2007 2:39 pm 
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ok have taken some pic's of my repair... hope they are helpfull...

 

 

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Posted: Sun May 13, 2007 9:40 pm 
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Krytox wrote:
I understand you can still purchase a premade fabricated plate from Ford.
And any backyarder can install it.


Thats true but the quality of them is a joke! its like a coke can in the strength department!
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Posted: Mon May 14, 2007 12:24 am 
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ive done the same thing i used a cable plate from a n13 pulsar i modified it slightly and its all good now..

 

 

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Posted: Mon May 14, 2007 7:43 pm 
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My EA has been welded in the past.. looks solid tho.

 

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