Not sure if anyone else has had this problem, with the Mk5 Clutch pedal modification - for the AP Organic clutch.
The nylon quadrant in the clutch pedal has exploded into little pieces and the pedal is now sat on the floor

Am not sure this mod was done right in the first place, as the pedal has always felt loose and moves side to side on the assembly

Have looked in the Haynes manual, but there are several washers and plastic rings (different colours) - isn't clear which order they go in


Does anyone have a picture of a std s2 pedal assembly, looking up the dashboard?

 

did u ever get that butchered release lever sorted? I'm pretty sure ur dad did the rest right.

 

Replaced my bespoke release arm eventually at the start of this year - but didn;t make any difference to how loose the pedal was.
Think cable has stretched?? Most stuff has been on the car from new or replaced at about 100'000 miles, it's done over 188'000 now, so cable is probably not in the best state. Should replace it, then i know it's right

Dad, Oli and a few others i asked have outright refused to ever do this job ever again!! Tis a bit nasty
Getting sorted at weekend hopefully

 

the quadrant needs a a section cut out of it, on the other end of the adjuster bolt you need to put a cvh rocker nut on the wrong way round so the cut part of the quadrant hasn't got a sharp edge pushing against it.

 

This could be where i've gone wrong - i remember it saying on AP's website about putting a nut on the end of the adjusting bolt in the pedal..oops!

Think it's funny have been repeatedly warned about blowing my gearbox and have seen off part of the clutch pedal first Good old PE gearbox

 

Quadrant was cut 10 teeth in, as per instructions

 

everything is right, apart for u need to add some packing washers either side of the pedal, as it's narrower than the std one. U defo should put a new clutch cable on, as they are under more stress with the heavier plate, and snap with fatigue. after a while. A longer/stretched cable means it will bite lower to the floor, but wont effect the play in the pedal.

 

Interesting view...

Thought the whole idea of this mod was to get rid of the auto adjustement...if this is the case then the stretched cable wont have much bearing on the clutch movement unless its out of the scope of adjustment.

The cable is also strong enough for the application and should only snap if its fouling on something, or getting very hot and melting inner to outer cable. (sheilding)

SO if its in the length that can be ajusted for the pedal to work to suite the driver then the cable does not need replacing.

 

The idea of the mod is, because the way AP have designed the cover, the std pedal mechanism will not disengage the clutch fully even with the pedal all the way to the floor. The std ratchet auto adjustment is a pain, so even on a srd clutch u could use this mod to get rid of it. On an AP clutch u have no choice, u have to go manual. The mk5 quadrant is cut down so that you have enough movenment, and the the pedal doen't sit too high.

A stretched cable won't have much bearing - as u can manually adjust to compensate, so the clutch bites at a comfortable position.

Replacing is done for 2 reasons. First, if it's old, then a new cable will give a more fluid movement due to less friction internally. Secondly, it's working a lot harder with a heavier cover, it's under more stress full stop. I had one snap a few months ago - it lasted 4 years and i do a lot of traffic driving so it does get used a lot. I know other people who have had them snap too. For the price of the cable, i think it's a worthwhile precaution.

 

this any use?

http://cgi.ebay.co.uk/FORD-ESCORT-RS...QQcmdZViewItem

 

Does this help? Probably not







Rotate head 90° counter clockwise

 

Rick there is nothing wrong with the cable.....why would you replace something that isn't broke ? Do you work for an MOT station or somert

 

Thanks Tony, almost
Is all back together correctly now and the annoying vibration noise has gone - so am happy

Just for anyone interested and reference

 

 

somethin else the claws had his hands on lol