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About 5 months ago I snapped a clutch cable in my 92 Geo Metro 5 speed, pulled the transmission and the clutch was well worn so we replaced the clutch and cable, I started noticing the clutch pedal getting harder to push in, in the last month or so. Not so much when it was "cold" but after a few hours of city driving it would get "tighter".

The 5 month old cable just snapped! I'm sure the clutch itself is fine as I have never worn one out quickly. What could be the reason this time for the cable to get so tight as to snap so quickly?

I'm suspicious of our initial clutch cable installation, we could have installed it with too little play, I remember the clutch pedal height being an inch so too high but couldn't get the pedal to go lower by adjustment, anyone got any ideas? I'm going to replace this one tonight but fear this problem may reoccur too soon. It is a mechanical clutch not hydraulic. - Dale

Dale,

Sorry to hear you're having trouble with the Geo.

While I'm not familiar with the specific setup, you may want to check these things.

1. Match up old cable with new cable and make sure they are the same length.
2. Make sure you have the cable routed and connected in the same way - check if the cable is routed in such a way that it binds or puts an extra load on the cable.
3. If you replaced the clutch disc, was it put in the right way - usually they are marked for the engine facing side and/or gearbox facing side, if installed backwards it may be pushing against the pressure plate.
4. If you only did just the clutch disc, you may want to consider replacing the whole kit - clutch, pressure plate and throwout bearing. The pressure plate might be broken or binding (and not noticed upon a visual inspection). Ditto for the throwout bearing.
5. Make sure that the release lever on the trans that connects to the cable moves freely - a dab of grease/lube here helps, not too much, you don't want any finding it's way on the disc.

I hope this helps - if you run into anything more specific let us know and we'll help you through it.

Hi Dale, when you pull the gearbox again you will have to lube the pivot points on the clutch release arm and also the splines where the clutch plate and release bearing slides on the input shaft in the bell housing. You just need to wipe a small amount of copper antisieze on these points so you do not contaminate the clutch plate and fly wheel.

Good luck, Chris.

Thanks for the advice nervousmini and Neddy Seagoon,

I did install the whole kit the last time. It is installed correctly (presumed as it's a simple task I've done many times on multiple cars and it otherwise disengages/shifts perfectly, though I would for curiosity's sake like to see how much grease is on the input shaft but don't want to pull the tranny for it.

Old and new cables match.

Cable routing may have been an issue more than anything.

I took the clutch pedal assembly out and found a sharp burr from the clevis pin rubbing on the pedals "hook for cable" area. I filed the burr and greased lightly. It was a real mf'er to get under the dash with a flashlight balancing on my neck/head and reinstall the spring loaded pedal with a bolt that was just a hair too long to make it easy and no room to get more than a few fingers where you wanted them. Once I gave up on the flashlight and used a shop light (duh) my range of motion and determination improved enough to finish it.

clutch cable replacement
time: 20 minutes
cost: less than $20.00

clutch pedal assembly removal, service, and reinstall
time: 20 minutes removal, 10 minutes service
and for reinstall 3 hours of cussing, contorted back, shoulder, neck pain, near death loss of blood to extremities, cut fingers from sharp edges of brackets or invisible teeth of guardian demonic japanese dragon protectors of clutch pedals, 5 beers, a temper tantrum, more cussing directed at all things small, Japanese and invisible, a moment of clarity and 20 more minutes later, bitter success.

All in all it was horrible but if I had to do it again maybe an hour total but it would still be a horribly tortuous task.

Picture a monkey holding an apple stuck in a hollow tree full of stinging bees, who refuses to turn loose of the apple for fear of losing it but can't get it out for the size of the hole and his apple fisted hand.

Perhaps your asking yourself why there is a tree full of swarming bee's and an apple in this tree? This is what I was asking the evil f'n engineers at an obviously karma related closed Geo plant somewhere in Japan the other night. I really don't know I'm just the monkey. :eyebrow:

Next time I go to the Pull-A-Part junk yard I'll pull another clutch pedal assembly for a spare. Removing is fairly easy, getting the loaded spring and pedal centered for the bolt to slide through the hole of the bracket and pedal assembly and other side of the bracket is less easy.

It shifts great now but I'll be monitoring closely as it was good for a while before. :D - Dale

Hi Dale, sounds like you have it licked. Hope it all works out for you, at least it's not a slush box ( Auto Trans ) those things are nasty. My family only drive's stick shifts, its a Limey thing!

Chris.

http://teamswift.net/viewtopic.php?f=22&t=47372

and slideshow (http://www.flickr.com/photos/drimportracing/sets/72157623660339661/show/with/4495970513/)


msirach,
To quote a world famous nuclear technician/safety inspector of section 7G for the Springfield Power Plant.

"Beer, the cause of and solution to all of life's problems." - Homer Simpson

This job took 3.5 beers. :D - Dale