clutch problem - cable?

BX Tech talk
andycadabra
BXpert
BXpert
Posts: 288
Joined: Wed Dec 21, 2005 6:01 pm
Location: Kennington, London
x 1

clutch problem - cable?

Post by andycadabra » Wed Jan 27, 2016 9:50 pm

Lost control of the clutch the other day. The pedal went floppy and the recovery guy reckoned it was a broken cable.
However, after removing ducting at the gearbox end, I videoed the cable while I went to operate the pedal, and it's moving about 8mm, which suggests it's not broken?.

Described the problem to one garage and he suggested it could be a broken plastic quadrant. However looking through the parts catalogue, there is no mention of a quadrant.

I tried adjusting the clutch a bit, but this seemed to have no effect on increasing the firmness of the pedal, and just reduced the movement of the cable at the gearbox end to about 4mm.

The clutch was replaced about 10,000 miles back, ( it didn't need to be but was done during engine change).
Any ideas anyone?
1992 BX 17TZD 130k
1987 BX 16TRS SORN

User avatar
ken newbold
Over 2k
Posts: 4408
Joined: Sun Aug 14, 2005 10:53 pm
x 5

Re: clutch problem - cable?

Post by ken newbold » Wed Jan 27, 2016 10:20 pm

Sounds like the bracket on the back of the pedal has gone awol.

The cable sits in this bracket and is actually in the engine side of the bulkhead. However you access it by way of removing the pedal box, easy enough to do. Disconnect the clutch cable at the gearbox end. Then remove the two allen screws facing upwards and two 10mm nuts facing forward, these hold the pedal box in place. Disconnect throttle cable and pull/ease the pedal box towards you helping the clutch cable through the bulkhead as much as you can. If the bracket is broken or best you'll now be able to see it.
They think it's all over, it is now!

andycadabra
BXpert
BXpert
Posts: 288
Joined: Wed Dec 21, 2005 6:01 pm
Location: Kennington, London
x 1

Re: clutch problem - cable?

Post by andycadabra » Thu Jan 28, 2016 1:03 am

thanks for the quick and useful reply, Ken. it looks like a fine day tomorrow so I'll have a go, and report back.
1992 BX 17TZD 130k
1987 BX 16TRS SORN

kernowtim
Confirmed BX'er
Posts: 78
Joined: Thu Oct 23, 2014 10:08 pm
Location: cornwall
My Cars: BX 19 estate
1999 ford focus 1.8TD

Re: clutch problem - cable?

Post by kernowtim » Thu Jan 28, 2016 1:27 pm

had a similar problem years ago on my first 1.9d, one of the the 'lugs' that retain the outer cable had broken off on the pedal box, pedal box had to be removed from inside the engine bay and welded. the refitting method shown in the haynes book was for very early cars and didnt work on my 1989 model as i eventually worked out!! pedal box had to be fitted in place then cable attached from inside engine bay and the rubber seal and plate refitted,was a fiddly job as space limited!!
Last edited by kernowtim on Thu Jan 28, 2016 3:07 pm, edited 1 time in total.

User avatar
Kitch
Over 2k
Posts: 6207
Joined: Sun Jul 03, 2005 9:36 pm
Location: Fareham, Hants
x 49

Re: clutch problem - cable?

Post by Kitch » Thu Jan 28, 2016 1:32 pm

It doesn't have a quadrant. He's thinking of Sierras!

andycadabra
BXpert
BXpert
Posts: 288
Joined: Wed Dec 21, 2005 6:01 pm
Location: Kennington, London
x 1

Re: clutch problem - cable?

Post by andycadabra » Thu Jan 28, 2016 11:16 pm

you guys were spot on! got the pedal box off, and it was clear that the 'cable sleeve retaining ring' had broken and bent, as shown in the pictures.
should it be done by an automotive welder or will someone who does wrought iron work be just as good?
I'm wondering if I should replace the cable as its detached at both ends (though I've heard it takes a rather convoluted route) as 1. I'm not sure there's enough of the white plastic part that fits inside the ring - see photo, 2. a couple of strands are broken at the pedal end, and 3. the cable operation is smooth but it feels a bit resistant.
I had problems locating the right replacement cable that was long enough, 6 years ago, and uploaded a picture of the old one to photo bucket which I've included here.
if I do change the cable, I had the idea of withdrawing the old cable with a length of wire attached, which I can then disconnect and connect to the pedal end of the new one to pull it through from inside the car. Would this make it an easier job?
http://s951.photobucket.com/user/andyca ... sort=1&o=0

http://s951.photobucket.com/user/andyca ... sort=1&o=0

Image
Image
http://s951.photobucket.com/user/andyca ... sort=1&o=1

http://s951.photobucket.com/user/andyca ... sort=1&o=2

http://s951.photobucket.com/user/andyca ... sort=1&o=3

http://s951.photobucket.com/user/andyca ... ort=1&o=10
sorry these haven't come out as photos or links. I tried the Img button first, and then URL but still they don't seem to be clickable. If anyone knows what I'm doing wrong please tell me
Last edited by andycadabra on Sat Jan 30, 2016 7:13 pm, edited 4 times in total.
1992 BX 17TZD 130k
1987 BX 16TRS SORN

Defender110
Over 2k
Posts: 5898
Joined: Wed Dec 16, 2009 8:02 pm
Location: Harwood, Bolton
My Cars: Citroen BX MK1 Break.
Land Rover Discovery Series 1 200tdi 3 door
Land Rover Discovery Series 2 Facelift TD5
BMW X1
x 25

Re: clutch problem - cable?

Post by Defender110 » Fri Jan 29, 2016 2:43 pm

Photobucket appears to be down which might be affecting your images?
Kevan
1987 Citroen BX MK1 diesel estate.(Currently in dry storage)
1997 Mercedes C230 W202 - daily driver.
2010 BMW X1 SE 2.0D Auto - Her indoors daily driver.
2003 Land Rover Discovery Series 2 Facelift TD5 - Daily driver / hobby days and camping.
1993 Land Rover Discovery 200tdi Series 1 3 door - in need of TLC

User avatar
ken newbold
Over 2k
Posts: 4408
Joined: Sun Aug 14, 2005 10:53 pm
x 5

Re: clutch problem - cable?

Post by ken newbold » Fri Jan 29, 2016 9:04 pm

if you've got broken strands, change it now before it lets you down. The route of the cable is fairly straight forward, the worst part is getting it to stay located in the pedal box while you refit it. Someone to help you is useful as they can keep the tension on it by pulling the inner cable while you get it refitted.
As for welding it, anyone who can weld should be able to do this.

Photobucket is still down, but think it will work if you delete the url & brackets at the beginning and end.

http://s951.photobucket.com/user/andyca ... sort=1&o=0
They think it's all over, it is now!

andycadabra
BXpert
BXpert
Posts: 288
Joined: Wed Dec 21, 2005 6:01 pm
Location: Kennington, London
x 1

Re: clutch problem - cable?

Post by andycadabra » Sat Jan 30, 2016 1:55 am

thanks for the advice Ken. Photo bucket is still down, so I'll try again as soon as it's ok. The pedal box has been welded already by a local garage, though I haven't picked it up yet. I noticed the cable is a bit stiff to operate, even when disconnected from the clutch, and I just about recall an episode 6 years ago when I had a cable fitted by a local cowboy garage. amongst the various things they did wrong was fitting the cable so that its follows an 'S' shape at one point. docchevron advised me to refit it, and if I didn't it could result in a bend/fracture of the pedal box,
I'd be wary about leaving the cable routed like it is longterm, it could bend / fracture the pedal box (especially since the bracket the cable butts against is weaker than a cheese slice from "poverty sandwiches"..
http://www.bxclub.co.uk/forum/viewtopic ... 5&start=30
which is exactly what happened!. so I'll get a new clutch cable (it needs to be 1.4 m apparently- the first one I got back then was too short) and drag some wire as I planned, to trace the current route of the cable, but then use my common sense to re-route the new one to avoid sharp bends.
1992 BX 17TZD 130k
1987 BX 16TRS SORN