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big clutch pedal/cable problem

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DAC1138

big clutch pedal/cable problem
« on: February 20, 2007, 03:01:14 PM »
So just today I've had my second clutch cable break on me. Let me recap my difficulties with my clutch.

About 6 months ago, my clutch cable broke. My dad and I replaced it, and all was good for a while.

About 5 months ago, my clutch pedal completely broke, and needed replaced. The metal shaft for the pedal just twisted apart. So I've replaced the pedal since then, and all was good for a while.

about a month ago my clutch pedal broke again. It broke in a different part of the shaft, but it still broke. It looked like a really bad welding job, but I can't say if that was the cause of it breaking. I had my friend's dad weld it back together for me.

Just today, my clutch cable broke again, and I've had to replace it again.

My uncle says that the problem might be the clutch disc pressure plate being worn out. It's causing too much stress and strain on the pedal and cable whenever I push in the pedal. Could this be the problem? Has anyone else experienced something similar? Is there any way to fix the pressure plate or resolve the problem without replacing the entire clutch kit? It currently has 152k miles, but the clutch disc doesnt need replaced. Its not worn enough.
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Offline jzap

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Re: big clutch pedal/cable problem
« Reply #1 on: February 20, 2007, 03:44:44 PM »
I haven't had the problem you are describing, but on another forum, it was stated that the clutch pedal mechanism on the '96 and older was a bit weak, and that if you replace it, you should use a '98 unit, which is supposedly built stronger.  I'm sure that someone who knows more than I do will pipe up, but 152K on a clutch sure seems like it's due for replacement...
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Jim Z.
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Offline Amilla

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Re: big clutch pedal/cable problem
« Reply #2 on: February 20, 2007, 04:23:31 PM »
ya i agree, that is quite a few miles on a cluth.

Amilla
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88 Samurai, Sprung Up, Geared Down, Locked,With Yotas.
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DAC1138

Re: big clutch pedal/cable problem
« Reply #3 on: February 20, 2007, 04:25:00 PM »
Quote from: jzap on February 20, 2007, 03:44:44 PM
I haven't had the problem you are describing, but on another forum, it was stated that the clutch pedal mechanism on the '96 and older was a bit weak, and that if you replace it, you should use a '98 unit, which is supposedly built stronger.  I'm sure that someone who knows more than I do will pipe up, but 152K on a clutch sure seems like it's due for replacement...

I had that thought, actually. I was looking to replace the pedal from a junked car. Problem is, those are hard to find around here, especially a newer 98 model.

But how does that explain the clutch cable breaking? I love the thing to death, but every single problem I've had with the car has been a clutch problem. never an engine fault or anything else. Just the clutch system.
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Offline takai

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Re: big clutch pedal/cable problem
« Reply #4 on: February 20, 2007, 04:34:19 PM »
At 152K, I think that I would plan on replacing your clutch. The complete kit isn't that expensive and your clutch has more than its fair share of miles. You might discover that your problem is greatly lessened with all new components. If you are going to change out that pedal give a Hawk a call, I am positive that they will have the parts that you are looking for.
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Offline mrfuelish

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Re: big clutch pedal/cable problem
« Reply #5 on: February 20, 2007, 05:21:51 PM »
It could also be the throw out bearing binding on the input section of the transmission, petroworks sells one for a samurai that has bronze on it instead of aluminum that does not like dirt and wears fast call them and see if they can do a tracker.
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1987,1988,1988,1990 samurai's,  1953 m38a1,  1996 x-90,blue.1996 x-90 red.1994 2 door tracker.   only Dead Fish go with the flow.                No Hairy Nosed Wombats were ran over on the trail today.       My ZUK is Xenophobic.
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DAC1138

Re: big clutch pedal/cable problem
« Reply #6 on: February 20, 2007, 08:35:17 PM »
How much should the clutch kit cost? (kit, being the disc and the the pressure plate, and the alignment tool, etc...) I've been shopping online and have seen it for about $150, but I know they can be found cheaper. Any helpful links?

Also, since I've replaced the cable, I now have a strange metallic clicking/tapping that comes from the pedal when I let up on it. Should I worry about this?
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Offline mrfuelish

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Re: big clutch pedal/cable problem
« Reply #7 on: February 20, 2007, 09:55:48 PM »
sounds like you wore through a couple of fingers on your pressure plate, I run the petro works dual friction disk and matching plate, cheap is not cheap when ya do it twice.
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1987,1988,1988,1990 samurai's,  1953 m38a1,  1996 x-90,blue.1996 x-90 red.1994 2 door tracker.   only Dead Fish go with the flow.                No Hairy Nosed Wombats were ran over on the trail today.       My ZUK is Xenophobic.
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Offline takai

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Re: big clutch pedal/cable problem
« Reply #8 on: February 21, 2007, 08:36:10 AM »
Quote from: mrfuelish on February 20, 2007, 09:55:48 PM
sounds like you wore through a couple of fingers on your pressure plate, I run the petro works dual friction disk and matching plate, cheap is not cheap when ya do it twice.

A good call there. The stock ones aren't bad but, they don't last or perform as well as some the aftermarkets. I am partial to Centerforce clutches I have run them on just about every rig I have owned and they have always performed well. Cheap they are not but, IMHO they are worth it.

Just my .02
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87 Sammi "Sir Tweak " Rockcrawler 4:1, Mighty Kong , 1.6 16V, Centerforce II, 2" Exhaust, Esteem seats. - Long gone
97 Tracker "Jezebel"  Bone Stock DD

'Cause, I am to misbehave.
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DAC1138

Re: big clutch pedal/cable problem
« Reply #9 on: February 21, 2007, 03:33:49 PM »
I would go with the high performace clutches, but I'm on a really tight budget.  Long story short, I'm underpaid and underworked (working 8 hours a week) So how much do the standard clutches run? Any cheaper than $150 like I'm seeing?
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Offline mlovetripp0

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Re: big clutch pedal/cable problem
« Reply #10 on: February 21, 2007, 09:28:25 PM »
i paid $125 for a stock clutch from oreilly's
but it did not last long
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87 sammi
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DAC1138

Re: big clutch pedal/cable problem
« Reply #11 on: February 22, 2007, 07:06:01 AM »
since installing the new clutch cable, whenever i push in the pedal now it's a lot softer and easier to push it. it just glides to the floor and it feels so much better. there's almost no stress on it at all. how could a cable make such a difference in the way the pedal feels?
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Offline chet

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Re: big clutch pedal/cable problem
« Reply #12 on: February 22, 2007, 08:41:03 AM »
the old cable probably had a broken wire that was catching on the cable housing and causing a tight spot. been there done that!  ;D
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1991 4 door kick, 2" coil spacers, 30" Coopers, winch, locker, rust, dents, etc.
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DAC1138

Re: big clutch pedal/cable problem
« Reply #13 on: February 22, 2007, 07:00:37 PM »
Yes, the new cable lets the clutch pedal just glide to the floor. This feels so much easier and better. Now could the pressure plate still be the problem? Or could I just have bad luck and have gotten defective cables and pedals? Take note that the replacement pedal i got had a bad weld. I'm not a welder, but I could see it was barely hanging on (but i trusted the suzuki parts dealer)
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Offline Bobzooki

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Re: big clutch pedal/cable problem
« Reply #14 on: February 23, 2007, 07:23:09 AM »
My 95 4-door, with 185,000 miles on it, is still on the original clutch.
I just replaced the clutch on Mrs. Bobzooki's 99 GV (With 172,000 miles on it.)
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Bob

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