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cosworth 4x4 clutch cable replacement!!

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Old Jul 15, 2008 | 06:44 PM
  #1  
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From: Stoke on Trent
Default cosworth 4x4 clutch cable replacement!!

Clutch cable snapped yesterday Inconvenient obviously as i came home on a tow truck!! As im living with a friend i dont have garage or tools and only gravel drive so couldnt easily do a repair so i entrusted it to the local garage. After all its only a clutch cable so a proper garage should be able to cope right??? wrong

Theyve fitted the cable fine but now cant get it in gear. Its an AP paddle clutch so I know its very stiff but they knew that so shouldnt have a problem. the way ive seen it done is vehicle slightly raised, spare bloke operates the clutch arm at the gearbox and holds it clutch disengaged then you play with the pedal accordingly with no heavy tension so the ratchet can operate, then release check, re-adjust etc etc.

Now ive tried to explain this and they going to try it in morning but the bloke doesnt really want to play around much as its not a standard car and i have a funny feeling he may not bother leaving me to fix it.

Now if i have to do it my thoughts are inside car, head in foot well, use pliers to pull cable into car from engine bay therefore releasing tension a bit so i can let the pedal adjuster ratchet away to get the necessary travel to disengage clutch at the pedal.

I dont really want to just mash the pedal, animal style and kill the traditionally weak pedal ratchet system as it is quite recent and appears visually to be in good nick.

Is there any easier way to do it??

Bearing in mind i dont have any tools other than my basic in the boot tool kit with pliers, a few common sockets, spare clutch cable and assorted bits and bobs!!

Long term hydraulic option is the solution but not right now!!!!

Any advice on doing this on the drive on me own would be appreciated!! I just have the feeling its an awkward fiddly pain in the arse job but if theres a knack to it then in "inside" know how would be great.
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Old Jul 15, 2008 | 09:23 PM
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From: Stoke on Trent
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anyone??
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Old Jul 15, 2008 | 09:54 PM
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Where is the car at Warren ? The method you describe above is the way. Changed my mates at Maccy's @ Crownhill
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Old Jul 15, 2008 | 10:42 PM
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From: Stoke on Trent
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im currently near doncaster staying at a friends!! I'll try and get them to do it on the ramp as its easier as theres really not much space under the dash to get me hands up there. I'll unbolt the seat for access if i have to so i lay on me back in foot well but i dont want to do that unless i have to!!!

LOL at doing it in Maccys car park!!!
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Old Jul 16, 2008 | 06:26 AM
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Just take out the lower dash section drivers side, put cable on gearbox end, secure with tape(technical bodge there!!) so end nipple does not come out, inside the car LIFT the cluth pedal past it's normal up position, this will release the ratchet, whcih you then PUSH(the ratchet) with your thumb forwards/downwards enabling the cable nipple to be put in tachet , release job done.
The only tool is a screwdriver to get off lower dash.
tabetha
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Old Jul 16, 2008 | 09:08 AM
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Or, I've done it the other way by lifting the pedal up high, and putting a brick under it, thread cable onto ratchet, then push cable onto clutch lever at the gearbox end, remove brick - job done
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Old Jul 17, 2008 | 06:04 PM
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From: Stoke on Trent
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got it done and cables already stretched Ratchets as far as it can go and still not fully disengaging now!! Now dumped the car at reylands to get it properly sorted clutch wise!!.
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Old Jul 18, 2008 | 06:16 AM
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You can also sort this problem by cutting a slit in a 13mm nut then place this betweent he arm and cable nipple so it takes up the slack, de tension the tensioner press pedal a few times job done.
tabetha
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Old Jul 18, 2008 | 09:03 PM
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From: Stoke on Trent
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thanks tabetha!! sounds like a good temporary fix!!

Im hoping its sorted soon with either a strengthened cable and some pedal mods or a hydraulic conversion if Martin can make space for it in my car as the down pipe is kind of in the way at moment.
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Old Jul 19, 2008 | 07:35 AM
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I used a sherpa master cylinder, with mgbgt(v8) slave cylinder on my dads xr4i(rover V8) on his, cost well under £100.
tabetha
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