Manual pedal assembly failing

[redspire]

Over the summer i ran into a slight problem that is turning out to be a bit worse than i thought at first. On my 97 aspire, the clutch cable runs into the firewall and there it meets the pedal assembly at a bracket. This bracket is what keeps the proper tension on the cable to keep it on the pedal assembly. The problem lies in the fact that Ford thought that a small weld on either side of this bracket would withstand years of pressure from the human foot. Over the summer both of those tiny little dots called welds broke and that left me no other option but to rig it up by drilling some holes and bolting it in place. It was a good temporary fix, but for some reason the pedal keeps losing pressure and i have to keep tightening up the clutch cable. Lately I've realized that the pedal has felt a little weird, so i took a look at it today and saw that the pedal assembly on the clutch side is bending a bit.
Guys, i need a solution, should i buy another pedal assembly and hope for the best in that the events don't repeat themselves, or is there a stronger solution i.e. aftermarket pedal assembly made of tougher material? I can try to upload pics later if needed, and i thank you all for all input!

[bravekozak]

Time for a hydraulic clutch conversion.
It reminds me of the time the clutch pivot weld broke on my 81 Malibu and I had to drive home in second gear all the way. I had to take it out and have it rewelded.
Welds weren't meant to take that much punishment. Too bad all of out parts couldn't be six axis CNC aerospace machined out of solid metal.

[redspire]

Is there a write up on hydraulic clutch conversion? If so, where?

[scitzz]

I broke one on mine a few years back, I still have it. My problem was the cable was corroded, and it was putting too much pressure on the pedal.

[bravekozak]

http://www.fordfestiva.com/forums/showthread.php?30593-FS-Hydro-to-Cable-Clutch-Adapters&highlight=hydraulic+clutch

http://www.fordfestiva.com/forums/showthread.php?525-anyone-else-using-obd2-or-a-hydraulic-clutch&highlight=hydraulic+clutch

http://www.fordfestiva.com/forums/showthread.php?48716-Hydraulic-escort-gt-transmission&highlight=hydraulic+clutch

http://www.fordfestiva.com/forums/showthread.php?25005-Brake-upgrade-and-hydraulic-clutch&highlight=hydraulic+clutch

[getnpsi]

Pressing down will still bend assembly cable or hydro. remember you use brskes too. Take it out and reinforce it. Same hapened to me with aspire

[getnpsi]

4gh link. Try a mx3 next? I will if my festy bends on me

[redspire]

So does this mean i have to swap to a hydraulic transmission too? I'd like to keep my stock tranny?

[Bert]

There really shouldn't be very much pressure on that bracket! All it does is retain the cable sheath at a specific location. I had clutch cable problems a few years ago (frayed cable) and bent some stuff out of shape from excessive foot pressure just before the cable broke but when the cable and sheath were replaced (and the sleeves and retainers straightened out) everything went smooth as glass again. I'd be taking a good hard look at a new cable and sheath before contemplating a huge amount of work such as switch to hydraulic. I was lucky to discover that clutch cables from early Rios are perfectly compatible with Festys and likely will swap into an Aspire as well. Rio cables are bit longer than a Festy cable which should be good in your case. The U-pull near me charged me $1.99 for the used cable.
Good luck!

[1chrisapple]

U dont need a hydro conversion or a hydro trans.thats silly to me. Just get a new cable pull the pedel box out weld it and reinfore it a little and done.

[nitrofarm]

Time for a hydraulic clutch conversion.

http://youtu.be/2HJxya0CWco

[Bert]

Ya gotta love progress. In the old days of mechanical and cable connections (gas, clutch, choke etc) you could always Jury-rig something with fishing line, string or coat hangers etc etc to help get you home but with hydraulics you are totally screwed.

[redspire]

Is there a write up on Pedal Assembly Removal? So my cable could be shot then if it's putting that much pressure on this bracket? Good to know guys, thanks!

[scitzz]

Cable or something with the clutch assembly, like a throwout bearing. It should be pretty easy to press the clutch pedal.

[redspire]

And if its the throwout bearing? I'm better just to replace the clutch too at that point right?