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Firewall cracked/bent - clutch cable snapped - other question. 200



My 4 month old Gemo clutch cable snapped clean at the metal piece that hooks onto the top of the pedal. I only had to tow it a few blocks which was lucky. But I'm confused because on my 86 there is a weight holding the cable to the fork. Either that weight is now lost ( went looking for it) or it only requires the washer and small square rubber piece. I can't recall what it needs exactly. Hopefully the weight is not lost.

Also with that I found my firewall which was fine 4 months ago cracked and bent an inch or more. I know of a welder that hopefully can get it fixed before a new cable arrives. But I'm wondering if I need to do anything special for it other than just have it welded. Welder will most likely have some solutions but just wanted to hear from the experienced.

I just added a spring to the clutch fork and wondering if the extra pressure on the pedal caused the break. This is my second clutch cable this year to break at that spot except this one snapped clean rather than frayed. I just thought the cable kept loosening. Thanks.








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Firewall cracked/bent - clutch cable snapped - other question. 200

This is the '83? I see it in some of your threads.

There is no hunk of metal at the outer end of the fork so look no further. I think '86 was the first year for that feature.

Your car is supposed to use a clutch return spring. I don't see how the ones sold specifically for this purpose could have caused the clutch cable to break. What kind of spring did you use?

Anyway the fork will only return so far. Was it adjusted properly?

Snapped clean is odd, though. Frayed you expect. Manufacturing defect maybe?

No thoughts on the firewall. It's difficult to envision.
--
'80 DL 2 door, '89 DL Wagon








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Firewall cracked/bent - clutch cable snapped - other question. 200

The spring was correct but added extra resistance to the pedal. I just added it a couple weeks ago which makes for a having to press harder on the pedal and that would make for more pressure against the firewall. The firewall didn't break at the actual hole but a couple inches towards center. It pealed it towards the driver so that it has a straight line cut and pealed leaving a hole into the cabin. The hole is about 3 inches long up/down and maybe an inch wide from engine to driver. I'll have to document it with photos and post sometime with before and after.

I thought the cable breaking like it did was strange and once I get the piece off the pedal I'll have to photograph it. Can't find a receipt for it but I believe the Gemo's have a 12 month warranty. I'm guessing though that the cable was on a strange angle to the pedal due to the firewall and could have caused it to snap. The only thing I can think could have happen.








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Firewall cracked/bent - clutch cable snapped - other question. 200

The firewall thing being the cause sounds very plausible.

But how did this condition occur?
--
'80 DL 2 door, '89 DL Wagon








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Firewall cracked/bent - clutch cable snapped - other question. 200

Unsure of why. No rust. But I have heard of it happening to someone else on the board before. I examined that area earlier this year due to a bad aftermarket cable not adjusting correctly. It looked fine then. I'm just glad that out of the past three fridays it happened yesterday. Two fridays ago I was 5 hours from home. Last friday I was 2 hours from home on a dirt road camping. So to have it break less than a mile from home makes it all a little easier.







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