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Clutch Cable replacement blunders


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12 replies to this topic

#1 gadberry

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Posted 19 November 2009 - 07:20 PM

My '81 GL Wagon clutch cable broke this week, but the GREAT NEWS is that
it broke in the driveway as I returned from work... so I ordered parts and
waited for the arrival, which was today..and the sun was shining so that's cool, right.. knock this puppy out over lunch..

so I read up on the replacement procedures in my "Compleat Idiot's Guide for Subarus"

here's how this simple procedure quickly became a huge PITA

While attempting to disconnect the "Clevis Pin" yoke connection at the clutch pedal, I realized the pin was installed with the head of the pivot pin sandwiched against the stamped bracket of the whole pedal assembly, which meant there wasn't room to back out the clevis pin enough to free the clutch cable. WTF!!

i thought, maybe I can swing the clutch enough to clear that bracket..

So after disconnecting a few plugs into the ECU and removing more dash hardware, I could *almost* swing the clutch pedal up and towards the drivers seat enough for the clevis pin to clear that freak'n stamped bracket that was blocking it's removal... but there still wasn't enough clearance for
easy removal

Much more shoving and prying with screwdrivers continued until it was forced past the bracket.. so 30 minutes later, I had finally removed the broken clutch cable...

upon comparison of the old cable to the shiny new one, it was obvious the new cable would not fit and was the wrong length.. what a kick in the pants that was!! :) back to part store; saturday delivery of new 'correct' part is scheduled... :rolleyes:

So, have I missed something obvious with the removal, or is this par for the course with Subaru clutch cables...

it could get worse, I'm not finished.. ;)

cheers,
gadberry

#2 GeneralDisorder

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Posted 19 November 2009 - 07:31 PM

They are always inserted with the head toward the pedal assembly frame. That's why you don't remove the clevis pin till AFTER you remove the clutch pedal from the assembly. It's a single E clip and the whole pedal slides off the end of the pivot.... You should read my clutch cable replacement guide:

http://home.comcast....ear/clutch.html

And you WANT an OEM cable. They are like $18. To the dealer my friend.....

GD

#3 gadberry

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Posted 19 November 2009 - 07:44 PM

oh that's gold!! :lol: the "idiot's guide" isn't simple enough for this idiot!! ha!

BUT that explains my WTF moment, and I did ponder the clutch pedal attachement for a moment, but thought "there's no freak'n way that has to come off for a cable replacement". :lol::lol::lol:

just what I get for rushing though a job, and topper for this blunder will be some electrical issue I have due to shoving the pedal up into the dash...

thanks very much for the clarification! I can't do anything but laugh at this point :lol:

peace,

#4 murph

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Posted 19 November 2009 - 07:47 PM

hey general ! , you rock , just enjoyed the how -2 on clutch cable replacement , great job - wish i would have had that availible when i did mine . i'm 6'3" - yeah it's tight in there . thanks again , very informative . murph

#5 GeneralDisorder

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Posted 19 November 2009 - 07:48 PM

I don't think I've seen this "Idiot's Guide".... is that a published item or an online resource?

GD

#6 GeneralDisorder

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Posted 19 November 2009 - 07:50 PM

thanks again , very informative . murph


No problem. I suppose my docs should be linked to the board somehow, but they aren't. I wrote that like 4 or 5 years ago.

GD

#7 Durania

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Posted 19 November 2009 - 08:16 PM

Its a great walkthrough, I followed it when I replaced the cable in my BRAT.

#8 GeneralDisorder

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Posted 19 November 2009 - 08:22 PM

We used to get a TON of questions on here about EA81 clutch cable replacement and a lot of very frustrated members - always getting the wrong cable from the parts guys and having a hell of a time installing them. Thus my install guide. It hasn't been a very popular subject in the last few years though. Probably a lot fewer EA81's left now. Used to be I could go to the yard and see half a dozen. Now it's a good day if I see a couple across several yards.

GD

#9 gadberry

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Posted 19 November 2009 - 08:30 PM

GD,
It's a hard-copy document

http://www.amazon.co...e/dp/0945465114

I've got a feeling when I get home tonight I'll find that it states "remove the
clutch pedal" in the book too.... ha!! :)

Your online guide to clutch cable replacement is great; thanks for that link!

best regards,
gadberry

#10 GeneralDisorder

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Posted 19 November 2009 - 08:39 PM

Oh! Yes, the HTKYSA. I have that in digital form :rolleyes:

I thought you were talking about something I hadn't seen. I should have known that such a thing couldn't exist :lol:

GD

#11 Dirk

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Posted 19 November 2009 - 08:44 PM

I've got that book! I think its great. Fills in most of the gaps from my Haynes manual. Not sure about all the Star Trek references though. The index is a funny read.

#12 gadberry

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Posted 22 November 2009 - 11:23 AM

OK, the clutch cable is installed, boy is it easy when you follow instructions
after GD's great step-by-step document was provided!

Thanks general disorder!

Btw- I did order from the dealer, but they sold an aftermarket israel-made
part that looked a bit sturdier than the Italian Luk brand I picked up
at autozone, which looked like the cable that failed.. Dealer part was 34 bucks
vs 16 at autozone

my cable failed at the clutch pedal bracket, the cable itself didn't break.

#13 GeneralDisorder

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Posted 22 November 2009 - 12:04 PM

Wow - your dealer doesn't discount at all! They are usually $10 or $12 cheaper than that at my local dealer.

Glad you got it fixed.

GD




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