| [ Total Views: 1436 | Total Replies: 23 | Thread Id: 78049 ] |
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 Anthiron
A.k.a.: Nicko McKay
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| posted on July 27th, 2009 at 02:08 PM |
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clutch has done something wierd??
So i was driving around as normal the other day, almost pulling into my driveway. went to change into 1st gear and pushed in the clutch. heard a funny
click sound and pedal went down almost to the floor before i felt a spongy bit of pressure. Got it into first a putted in and then had a fiddle.
it felt like a few strands had snapped on the cable as it went spongy and there was far too much travel, the way it was the clutch didnt fully engage
when depressed.
So i pulled out the old cable but it was perfect. not a problem with it that i could see. so i put it all back together and adjusted it tighter.
it now engages fine, and doesnt seem to slip but it feels very light and spongy.
before this happend it was very firm, almost heavy. i liked it that way.
thought it might have been the return spring on the fork arm but that looks fine too.
any ideas?
oh and the clutch is only brand new, professionally fitted a few months ago.
Nicko
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
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ancientbugger
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| posted on July 27th, 2009 at 05:34 PM |
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Could the cable have been fitted incorrectly the first time and just slipped into place now. Where the cable connects up to the pedal hook. I've
managed it in the past!! You haven't noticed any difference with the angle of the clutch lever at the gearbox I take it.
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Anthiron
A.k.a.: Nicko McKay
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| posted on July 27th, 2009 at 06:54 PM |
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im not sure about the angle of the clutch fork arm barry as i dont remember where it sat before. i suppose its possible but it lasted a few months the
way it was i would be surprised if that was it.
its got me stumped.
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
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Klaus
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| posted on July 27th, 2009 at 07:03 PM |
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the steel clutch tube in the tunnel has broken free, your going to have to cut 2 inspection holes into the tunnel on the pass side to access it to
begin the fun job of rewelding it to its supports. someone else may have the spots where the supports are located (havent done a beetle cable repair
for a while ) .
look at the bowden tube and see if its flat ie no preload , while your under there look for the steel pipe and see if it moves while someone else
pushes clutch pedal.
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Anthiron
A.k.a.: Nicko McKay
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| posted on July 27th, 2009 at 07:19 PM |
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the bowden tube still has bend is that what u mean by flat?
this sounds annoying.
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
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Klaus
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| posted on July 27th, 2009 at 07:29 PM |
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bend is good , other option is too pull inspection cover off in front of back seats and try and watch clutch tube while you depress clutch if it moves
its busted free ,
throw out bearing might have crapped itself but this is usually heard via a squeel and grinding feeling in the pedal.
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hellbugged
A.k.a.: Daimo Pell
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| posted on July 27th, 2009 at 07:33 PM |
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being firm and heavy before this incident i would blame the cable being installed with an issue from the first place..............is the hook on the
clutch pedal itself ok?
and it seems to be engaging alright now despite the softer feel?
but as Klaus says if it went ping and the cable is ok, fair call that it's the clutch tube........check weld under inspection plate and braket right
behine clutch padal hook........you can put another braket in the middle if the need arises, i can help out with location there if that turns out to
be the problem
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Anthiron
A.k.a.: Nicko McKay
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| posted on July 27th, 2009 at 08:01 PM |
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thanks for the tips guys ill suss it out tomorrow.
hook on pedal is in good condition.
how could the cable have been installed incorrectly? theres pretty much only one way to put them in?
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
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grumble
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| posted on July 27th, 2009 at 09:00 PM |
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If it is not the tube broken loose it may be a split pressure plate diaphragm giving the spongy low pedal.
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Anthiron
A.k.a.: Nicko McKay
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| posted on July 28th, 2009 at 11:20 AM |
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wouldnt it slip if it was the pressure plate?
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
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Anthiron
A.k.a.: Nicko McKay
Compulsive Aussie Vee Dubber
The Baja Rejuvenation Begins
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| posted on July 28th, 2009 at 11:51 AM |
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ok. so the tube is moving,
you can see it move through the inspection plate and more obviously through the inspection hole that the previous owner cut in the tunnel.
is this where it should be welded? (to the bulkhead it sits in at the front?)
are there only 2 mounts? because it looks like the rear is ok ( still bend in the bowden tube).
could any welder weld this up if thats the case and is the hole big enough for them to do the job without me butchering my tunnel?
Nicko
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
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ancientbugger
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| posted on July 28th, 2009 at 03:55 PM |
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Can't offer any help with the welding Nick but that is one hell of an inspection hole!!!
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grumble
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| posted on July 28th, 2009 at 08:51 PM |
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Yes if the pressure plate was split it would slip,obviously it wasn't this. A good welder with a mig will be able to weld carefully,watch the fuel
tube.A hole saw makes very neat inspection holes that can then be fitted with a rubber grommet. cheers les
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hellbugged
A.k.a.: Daimo Pell
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| posted on July 28th, 2009 at 09:56 PM |
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yeah Nick, the rear weld is under the inspection plate for the gear coupler..........that front inspection hole is like the grand canyon. i would weld
that back up being a baja, cracks could develop from there for sure..........holesaws are your friend for this reason, never seen a crack develop from
nice clean round hole yet, yes even left open
we like to take the wing nut off the cable and slide the cable back and forth as the tube is welded, preventing it being welded but also intruding
distortion/slag........
i slipped a tight fitting thick and large o.d washer over the front of the clutch tube (as per your pic, i actually cut the flared end off the tube to
have the washer fit really snug).......that way the tube is welded in an area away from where it was done before (to this washer) and you can lay good
weld around the outer of the washer to the flimsy bracket.........beats doing the two parts of the operation in one or two risky tacs
to take the pressure of the front and rear welds and stop the tube flexing, add a third braket while you are on the job........
......."middle" clutch tube braket added (this is in behind the passengers seat, 4 inch hole saw about 150mm behind the handbrake pivot
pin........pick out the flexing clutch tube and weld a 2 inch piece of 1 inch angle steel under it, pry down the clutch tube to the steel angle and
weld it to it CAREFULLY!).......
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bushed
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| posted on July 28th, 2009 at 10:09 PM |
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as for inspection holes it would be easier to cut 2 sides of a triangle with grinder and price out the piece to see.
lot less cuttin and weldin back.
Anyone think it may be a broken fork in bellhousing?
want any vw bits old but like me, Made in Germany!!!
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hellbugged
A.k.a.: Daimo Pell
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| posted on July 28th, 2009 at 10:34 PM |
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when the tube is getting loose and flexing, you have to wind up the wing nut beyond normal position, making clutch feel heavy..............then it
goes ping and pedal will be all spongy and inconsistent and at the very end of travel will go harder as it finally pulls the pressure plate just
enough to get a gear selected (feels a lot like broken cable)...........keep going with one broken mount on the tube, it will again go ping, and
clutch wont do anything as the tube travels where it wishes to....
sounds like Nicks description to me.........easier to weld it all up, as this will last if done correclty, than it is to pull the motor and go looking
for broken bits in there
broke the big steel ring that is between the two halves of the pressure plate that it effectively uses as it's pivot once...........pulled it all and
couldn't see any probs so we cut and drilled the pressure plate open to work out what had happened, that's what we found. was a wierd break, wish i
had pics
either way Nick, keep us informed as to what you find, always good to have an ending to these stories and can make a memorable thread to send someone
too in the future..........maybe I can tell bushed he owes me a beer on it when we come accross each other one day (maybe i could owe him one too  )
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Anthiron
A.k.a.: Nicko McKay
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| posted on July 29th, 2009 at 12:02 AM |
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ok ive found someone to weld it tomorrow morning hopefully.
ill keep you guys posted.
yeah that inspection hole is pretty messy, it was there when i bought the baja. i guess i probobly should neaten it up and round the edges and make a
cover plate for it.
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
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Anthiron
A.k.a.: Nicko McKay
Compulsive Aussie Vee Dubber
The Baja Rejuvenation Begins
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| posted on July 29th, 2009 at 10:25 AM |
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ok well i had it welded this morning.
ill take a pic today if i get a chance.
there are 2 individual beads of weld which look strong, im hoping it lasts. only cost 15 bucks.
i didnt do your washer trick joel, but if i breaks again ill go that way and put in a center mount.
it doesnt feel quite the same as before, i think the whole front bracket might flex a little.
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
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Joel
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| posted on July 29th, 2009 at 06:16 PM |
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credit daimo with that one not me 
funny what bushed says, was my first thought to
not broken but breaking fork
they sometimes make a nice mess when they go
i would just neaten up that canyon, not weld it up completely
always handy to have access there, really speeds up clutch cable replacements
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hellbugged
A.k.a.: Daimo Pell
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| posted on July 29th, 2009 at 08:26 PM |
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| Quote: | Originally
posted by Anthiron
ok well i had it welded this morning.
ill take a pic today if i get a chance.
there are 2 individual beads of weld which look strong, im hoping it lasts. only cost 15 bucks.
i didnt do your washer trick joel, but if i breaks again ill go that way and put in a center mount.
it doesnt feel quite the same as before, i think the whole front bracket might flex a little.
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does it feel lighter than before?
big washer helps stiffen that plate a bit too........not to worry.......next time ....glad youre on the road again
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Anthiron
A.k.a.: Nicko McKay
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| posted on July 30th, 2009 at 01:02 AM |
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ha ha my bad. joel, daimo, you are both too helpful to tell apart sometimes i guess.
i dont know if its lighter, dont think it is. i know i had to wind down the wing nut quite a bit more than before.
i only quickly adjusted it to drive out of the panel shop, ill give it a good look over tomorrow and get some pics up.
thanks again guys
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
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ancientbugger
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| posted on July 30th, 2009 at 09:18 AM |
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Hey Nick, now you're up and running how about a trip up the beach in a few weeks.
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Anthiron
A.k.a.: Nicko McKay
Compulsive Aussie Vee Dubber
The Baja Rejuvenation Begins
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| posted on July 30th, 2009 at 11:42 AM |
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sounds good barry, when were you thinking?
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
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ancientbugger
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| posted on July 31st, 2009 at 09:29 AM |
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I'm working the next couple of weekends then I'm off the following two weekends. I've still to get Mick onto the beach.
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