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> Clutch Failure, pedal to the floor!
mikedsilva
post Apr 17 2015, 05:04 AM
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I'm new to 914 and have no experience with gearboxes...
Tonight, my clutch failed.. the pedal went to the floor.
The cable is fine (new)... But turns out that the "fork" the cable is connected to in the gearbox, seems to pivot back and forth freely.

The clutch is still engaged but that fork piece doesn't appear to be attached to it.

With the basic description I have given, any ideas what it is?

Sounds like I will be doing my first gearbox removal...

Here is a link to a short vid I just took...

https://www.youtube.com/watch?v=F3sahANR2ow
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pilothyer
post Apr 17 2015, 06:49 AM
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Sounds like the clutch cable tube (inside the tunnel) has broken. If you can verify that it has not, you will be removing the transaxle to see what is wrong and it will be fairly easy to see. The clutch cable tube usually breaks free from the weld at the front and then the back at the firewall. Here is a picture of the tunnel (removed and up side down) the tube in question is the largest one in the picture.

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edwin
post Apr 17 2015, 06:53 AM
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Mine had a sheared ball pivot in the bell housing when I got it.
Could also be the pedal roll pin which will drop the cable tension as I remember.
Hydraulic is a nice fix if you can get your head around it.
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bandjoey
post Apr 17 2015, 09:44 AM
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(IMG:style_emoticons/default/agree.gif) easy to verify. Pull up the carpet, remove the inspection plates by the shifter, use Hand,mirror and light to find and wiggle the tube. If it moves let us know for further instructions.
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TheCabinetmaker
post Apr 17 2015, 10:01 AM
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Before you go pulling the trans axle, there are a few thing you can check. First, if the tube breaks loose from the front of the tunnel the pedal does not typically go to the floor. It just feels mushy. Check the roll pin at the pedal cluster. It might have broke. Is so, you can move the pedal while looking at the cable end visible from the front inspection hole. If the pedal moves and the cable does not, you lost the roll pin. Then check the trunnion that the cable goes thru at the clutch fork. I've seen that trunnion break and disappear. If it's Ok, remove the cable from the clutch fork. If it moves from one end of the hole to the other, your ball has broken or the plastic ball cup has dissentigrated.
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SirAndy
post Apr 17 2015, 10:41 AM
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QUOTE(edwin @ Apr 17 2015, 05:53 AM) *
Mine had a sheared ball pivot in the bell housing when I got it.

I've seen this happen too.

Time to drop the engine and tranny and get a good look ...
(IMG:style_emoticons/default/smash.gif)
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Dave_Darling
post Apr 17 2015, 10:59 AM
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(IMG:style_emoticons/default/agree.gif) with Curt (Cabinetmaker). Check the pedal first, because it's less invasive, but realize that odds are better than even that you'll be tearing the trans off the motor soon.

Fortunately that job isn't very hard.

--DD
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mikedsilva
post Apr 17 2015, 12:54 PM
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thanks for the replies but we have ascertained it is not the cable or the tube...
It's something in the transmission/clutch itself.

i will try to get the transmission out of the car this weekend...
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cwpeden
post Apr 17 2015, 02:04 PM
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Make sure to clean the CV bolt heads well and get the correct socket for them. Its called a triple square, 8mm I think.
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Brian Mifsud
post Apr 17 2015, 02:11 PM
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QUOTE(edwin @ Apr 17 2015, 05:53 AM) *

Mine had a sheared ball pivot in the bell housing when I got it.
Could also be the pedal roll pin which will drop the cable tension as I remember.
Hydraulic is a nice fix if you can get your head around it.


Me too... by process of elimination I found the nylon (original) "Socket" that that clutch fork pivots in had split. It was not a metal to metal fit on it's backside when new, in fact had about a 1/8" clearance on it's backside. When the nylon failed, the ball had nowhere to go but the WRONG direction. This amplifies the lack of travel in the RIGHT direction, so I could never fully disengage my clutch even with cable completely tightened up.

Dad's lathe and a chunk of bronze fixed that quickly. We machined a replacement that has no clearance behind it, and will outlast the car by lifetimes.

No need to go hydraulic on such a wimpy clutch.. we are only managing 80HP!
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mikedsilva
post Apr 17 2015, 03:28 PM
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I updated the first post with a link to a short vid I took with my phone...
Here is the link (i don't know how to embed)

https://youtu.be/F3sahANR2ow
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SirAndy
post Apr 17 2015, 03:31 PM
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QUOTE(mikedsilva @ Apr 17 2015, 02:28 PM) *
(i don't know how to embed)

It's in the FAQ subforum:
http://www.914world.com/bbs2/index.php?showtopic=97052
(IMG:style_emoticons/default/smile.gif)
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mikedsilva
post Apr 17 2015, 07:40 PM
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QUOTE(SirAndy @ Apr 18 2015, 07:31 AM) *

QUOTE(mikedsilva @ Apr 17 2015, 02:28 PM) *
(i don't know how to embed)

It's in the FAQ subforum:
http://www.914world.com/bbs2/index.php?showtopic=97052
(IMG:style_emoticons/default/smile.gif)


awesome.. thanks


https://www.youtube.com/watch?v=F3sahANR2ow
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euro911
post Apr 17 2015, 08:42 PM
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Yep, you need to pull the transaxle. If you rig or block the rear of the motor, you won't have to remove the motor and all the ancillary connections.
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ThePaintedMan
post Apr 17 2015, 09:33 PM
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QUOTE(euro911 @ Apr 17 2015, 10:42 PM) *

Yep, you need to pull the transaxle. If you rig or block the rear of the motor, you won't have to remove the motor and all the ancillary connections.


(IMG:style_emoticons/default/agree.gif)

At our Chumpcar race, we had a total clutch friction material failure. Probably because it was a used clutch that sat for awhile, it fell into a million pieces when we pulled the transaxle. The good news is a tranny can be pulled, clutch replaced and reinstalled in ~45 minutes if you have 4 guys who all know what they're doing. Still wish I had videotaped it. We had almost everyone under the car at one point, all tightening one thing or another. (IMG:style_emoticons/default/aktion035.gif)
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mikedsilva
post Apr 18 2015, 11:46 PM
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OK.
Got the trans out of the car easily enough... (the two bolts at the top had me stumped for a while...)

Here are some picks of what I found and short video to show the movement soon.
I'm too new to transmissions and this is the first I have ever pulled off a car, so I don't what these bits are meant to do...

It seems the clutch fork has come off the pin.. but how is this possible??
(IMG:http://www.914world.com/bbs2/uploads_offsite/i1260.photobucket.com-18462-1429422412.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/i1260.photobucket.com-18462-1429422412.2.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/i1260.photobucket.com-18462-1429422412.3.jpg)
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mikedsilva
post Apr 18 2015, 11:50 PM
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https://www.youtube.com/watch?v=mb0njVcypMA
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ndfrigi
post Apr 19 2015, 12:02 AM
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wow that is a super clean transmission after dropping it from your car. I assumed it was recently installed (maybe transmission was recently rebuilt or cleaned before you got the car).

In regards to that video, yes there is something wrong or maybe the recent installation was not done properly.

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euro911
post Apr 19 2015, 12:28 AM
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What's the part # on the lever? Looks like it's not long enough (IMG:style_emoticons/default/popcorn[1].gif)
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Tbrown4x4
post Apr 19 2015, 01:24 AM
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Looks like it might have been knocked out of place during installation. Was the transmission or clutch just replaced?
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