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ZUKIWORLD Discussion Forum => Suzuki 4x4 Forum => Topic started by: MKOLSEN22 on July 02, 2007, 07:44:20 PM

Title: Clutch cable troubles...
Post by: MKOLSEN22 on July 02, 2007, 07:44:20 PM

Last Saturday we went out to the Rexburg Rock Trail and joined up with some of the guys from Snake River Off-roaders and some more from the WOW club out of Utah. We ran the little Tracker over the milder portion of the trail and had a blast! It's fun feeling it bounce on the front tires as we're coming down the ledge.

Well later on that night I noticed that the clutch wasn't disengaging all the way when I had the pedal to the floor. Upon investigation I found the firewall was in bad, bad shape.

(http://i158.photobucket.com/albums/t101/Geotracker90/ClutchCable1.jpg)

I'm suprised that it didn't pull the clutch cable clean through!! This was also letting the cable wear through the cable housing. Ouch.

(http://i158.photobucket.com/albums/t101/Geotracker90/ClutchCable2.jpg)

I had moved the brake master cylinder out of the way and took the brake booster clean out of the little rig to gain some room to fix the problem. I grabbed some cardboard and made a template for a reinforcing plate.

(http://i158.photobucket.com/albums/t101/Geotracker90/ClutchCable3.jpg)

Long story short it got it all back together and it feels a lot stronger and should extend the life of the little truck a little longer.

(http://i158.photobucket.com/albums/t101/Geotracker90/ClutchCable4.jpg)

I did find one other problem that needs attention though. There is a clip that holds the brake lines to the firewall and they are almost worn through where the clip was. Well from one repair to the next.

(http://i158.photobucket.com/albums/t101/Geotracker90/ClutchCable5.jpg)

P.S. Also after completing the firewall repair at 3:30 am I was driving home when the alternator crapped out on me. Oh well.

Title: Re: Clutch cable troubles...
Post by: HotRod on July 02, 2007, 08:33:27 PM

Dang, thats one heck of a break and a nice fix job.
Heavy clutch foot? ;)

Title: Re: Clutch cable troubles...
Post by: MKOLSEN22 on July 03, 2007, 10:09:34 PM

Must have been from side stepping the clutch when taking off from every stop light and stop sign.   >:D ;D >:D

Thanks for the compliment on the fix.  So far so good.  The clutch feels lighter to push now as well.  Go figure.