broken firewall. CRACK!

[lyrinosis]

89 Kick jlx, 2-door, tin top, 4x4, 5-speed

Last year I had countless problems with the clutch - replaced clutch perfectly

more problems insued and found out the new cable was too long. Fixed that too

worked great for two months.

now the clutch cable pulled through the firewall. CRACK!
I welded some thick 1/8" plate steel with a hole for the cable to get in.
Worked for 2 days of hard work with a creaking sound coming from under the dash (cannot source the creak). Then it was hard to get into gear again! eventually impossible.

I adjusted so I get 1" travel on the actuator and the clutch pedal stops just above the break pedal. Works great for about 3 kilometers - then it starts to get hard to shift until impossible.

I use the pedal height adjuster and adjust it down again and again and again and now I have run out of adjustment for it. and it is STILL BELOW the break pedal.... worse yet, I have run out of actuator adjustment.

I just want a hydraulic clutch!

I want to drive my zuke off a cliff (with me in it)

I guess my question is: is there anything that can bend on the pedal height adjustment? that seems to be my problem.

[Rob]

Have you checked where the clutch pedal arm and clutch rod come together? Mine broke there last week. The weld broke that holds them together, not welded real good from the factory. It didn't just fall apart, just broke and allowed to two to slip in each other. Alot of people on here have had the end that hooks to the clutch cable either break off, or the splines strip off the shaft, oddly mine had no spline there, it was square on the end like 1/4" drive ratchet. All was well on that end luckily! Hope this might help, just a thought to pass along.

[Tracker Tommy]

This is actually a more common prolbem than not. I would check & try to adjust the spllen that hooks the clutch cable, that has always been my prolbem, they losed up & the teeth wear out over time, it's fairly easy to adjust, just don't take the nut & washer completly off, it can be a real pain in the ass to re-attach.

[lyrinosis]

I have adjusted the spline before, its not too hard. I will take clutch pedal components out this weekend and fix them... stay tuned for some panicked questions... It is parked for the time being because it wont shift gears at all now. I will weld anything that looks loose.

I will take a look at that arm for bad welds. Thanks guys