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In all my experience with 240s, I've never fought this battle. But if faced with it, I'd find a junked 240 and chop out the piece of firewall having the hole for the clutch cable. From my original (cracked) firewall I'd probably cut away only a clearance hole for the cable. Then I'd affix the patch to the outside of the firewall in my car (that is, under the hood, NOT under the dash).
I'd secure the patch using pop rivets and then slather on the paint, caulking, and undercoating to prevent water infiltration and rusting. The clutch cable would be retrained by the new patch.
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Don Foster (near Cape Cod, MA)
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