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Topic: PSA: Firewall ripped apart by clutch cable!!! (Read 8486 times) previous topic - next topic

PSA: Firewall ripped apart by clutch cable!!!

Okay I've been meaning to make a post about this for awhile.
 
This is (though not this bad which rendered the mustang undrivable) what happened to both my silver and black cougars.
 

 
 
In that corral thread, sure enough, the guy had a King Cobra pressure plate. I know the silver one has that, and the black car has some other super-heavy clutch. The silver one was worse because of the DUMB Steeda quick-release quadrant which has a bigger radius and applies the same force of your foot over an even greater distance just as fast, as well as due to its size, tugging the cable upward and grinding away at the firewall adjuster/grommet. The Maximum Motorsports clutch quadrant is a much better replacement for the stock plastic Mustang one. Look it up, they've put a LOT of thought into it and hell it's $39 as opposed to $79 for the Steeda one!
 
 
I didn't think to check the silver car until after I came home from LI getting the black one. The guy told me what happened to his car before he owned it, and, though not the cleanest looking fix, the owner before him had welded on a small piece of angle iron to s it up and sealed up and painted it all, giving that point lots of strength and it doesn't move at all. Sure enough though, sticking your head in there you can see where the silver car's firewall is starting to do what that mustang did. The MM quadrant made no difference in the pedal feel which isn't too surprising, but no more grinding cable. I had greased everything up before and was rotating the adjuster periodically to not wear a groove in it.
 
But the flex is ruining the throw of the pressure plate and shifting sucks. So I'll have to have that welded up and reinforced. Not the end of the world, but even at a little over 300 HP at the crank, this whole clutch setup is totally overkill and sure enough didn't it ruin something else.
 
Just something to watch out for if you have an upgraded clutch! Couldn't find a thread here anywhere about this, so I thought I'd mention it, plenty of us do 5 speed swaps all the time. Stop it before it happens!
1987 20th Anniversary Cougar, 302 "5.0" GT-40 heads (F3ZE '93 Cobra) and TMoss Ported H.O. intake, H.O. camshaft
2.5" Duals, no cats, Flowmaster 40s, Richmond 3.73s w/ Trac-Lok, maxed out Baumann shift kit, 3000 RPM Dirty Dog non-lock TC
Aside from the Mustang crinkle headers, still looks like it's only 150 HP...
1988 Black XR7 Trick Flow top end, Tremec 3550
1988 Black XR7 Procharger P600B intercooled, Edelbrock Performer non-RPM heads, GT40 intake AOD, 13 PSI @5000 RPM. 93 octane

PSA: Firewall ripped apart by clutch cable!!!

Reply #1 –
I thought you meant the clutch exploded. I knew a guy that lost his right foot when his clutch exploded in a mustang at the strip. The shrapnel almost cut the car in half.

But yeah, that's a good thing to keep in mind. I had a king cobra clutch with steeda quadrant and didn't even think of this possibility...
2015 Mustang GT Premium - 5.0, 6-speed, Guard Green - too much awesome for one car

1988 5.0 Thunderbird :birdsmily: SOLD SEPT 11 2010: TC front clip/hood ♣ Body & paint completed Oct 2007 ♣ 3.55 TC rear end and front brakes ♣ TC interior ♣ CHE rear control arms (adjustable lowers) ♣ 2001 Bullitt springs ♣ Energy suspension poly busings ♣ Kenne Brown subframe connectors ♣ CWE engine mounts ♣ Thundercat sequential turn signals ♣ Explorer overhead console (temp/compass display) ♣ 2.25" off-road dual exhaust ♣ T-5 transmission swap completed Jan 2009 ♣

PSA: Firewall ripped apart by clutch cable!!!

Reply #2 –
Just to point out a little inaccuracy in the 1st post that relates to the KC clutch. The KC clutch actually requires 10% LESS pedal effort than the stock one but has approx 30% more holding power. The rapid release quadrant is the main case for firewall failure as it applies a greater rate of release to overcome the resistance of the pressure plate....kind of like a stout cam profile working on a valve spring.
84 COUGAR/90 HO, 1.7RRs, performer RPM,700DP, equal length shorties, stainless EXH ,T-5,Hurst pro-billet, KC clutch, 8.8/ 4.10s, line-lok, bla ,bla, bla.
71 COMET/289,351w heads, 12.5 TRWs, 750DP, Liberty TL, 9"/6.00s, 11.9x @112 , bla,bla,bla.

Never shoot your mouth off, unless your brain is loaded! ....I may get older, but I'll never grow up!....If you're not laughing, you're not living!  :laughing:

PSA: Firewall ripped apart by clutch cable!!!

Reply #3 –
Quote from: Thunder Chicken;378723
I thought you meant the clutch exploded. I knew a guy that lost his right foot when his clutch exploded in a mustang at the strip. The shrapnel almost cut the car in half.

But yeah, that's a good thing to keep in mind. I had a king cobra clutch with steeda quadrant and didn't even think of this possibility...


Thats why I spent $450 on a bellhousing, someday when I actually drive my cougar (:( )it will be money well spent
[SIGPIC][/SIGPIC]

PSA: Firewall ripped apart by clutch cable!!!

Reply #4 –
I was riding a friend's quad once...we were racing in sand. the clutch came apart in the one I was on...thankfully one piece went out the front of the case and not up into my goodies.

What sucked was, MY old utility quad had to pull 2 broke-down quads 4 miles back to my place...


Now to the topic: I wonder if someone who was skilled enough couldn't make a piece (or 2) of of metal with the same contours, in a thicker gauge, and weld it into place?

Not sure if that would be a PITA, since the booster is right there, and the seam above...
'98 Explorer 5.0
'20 Malibu (I know, Chevy, but, 35MPG. Let's go brandon, eh)

PSA: Firewall ripped apart by clutch cable!!!

Reply #5 –
I'd be curious to see the clutch cable from that car. I've personally repaired guys cars where they were in such a hurry to install and drive that they never knew what the spacer washers in the quadrant kit were for. They are used to be certain that the quadrant pulls STRAIGHT and not to the side which will increase the force needed to pull the cable and exert enough side loading to cause failure at the firewall. Also, the best cable to use is the Ford OEM piece as they seem to hold up better than anything else @ the track. That's what I'm using on the street with my KC clutch and Ford racing quadrant and no problems to date other than adjustment for wear.
84 COUGAR/90 HO, 1.7RRs, performer RPM,700DP, equal length shorties, stainless EXH ,T-5,Hurst pro-billet, KC clutch, 8.8/ 4.10s, line-lok, bla ,bla, bla.
71 COMET/289,351w heads, 12.5 TRWs, 750DP, Liberty TL, 9"/6.00s, 11.9x @112 , bla,bla,bla.

Never shoot your mouth off, unless your brain is loaded! ....I may get older, but I'll never grow up!....If you're not laughing, you're not living!  :laughing:

PSA: Firewall ripped apart by clutch cable!!!

Reply #6 –
The OEM cable isn't adjustable, is it? And do you have a part #?

I still have the standard Tbird booster, but will be getting a Stang booster soon so I can use the firewall adjuster..would also like to get a backup cable just in case mine (of unknown make) breaks when I put the car on the road.

:)
'98 Explorer 5.0
'20 Malibu (I know, Chevy, but, 35MPG. Let's go brandon, eh)

PSA: Firewall ripped apart by clutch cable!!!

Reply #7 –
Quote from: ThunderbirdSport302;378751
The OEM cable isn't adjustable, is it? And do you have a part #?

I still have the standard Tbird booster, but will be getting a Stang booster soon so I can use the firewall adjuster..would also like to get a backup cable just in case mine (of unknown make) breaks when I put the car on the road.

:)
  You are correct in the need for a firewall adj as well as a smaller booster. I used a booster from an 86 Mustang GT, a cable from a 88 Mustang with over 120,000mi on it and any good firewall adj.

...this http://www.jegs.com/i/Ford-Racing/397/M-7553-B302/10002/-1?parentProductId=747130

...and this http://www.jegs.com/i/Ford-Racing/397/M-7554-A/10002/-1?parentProduc
84 COUGAR/90 HO, 1.7RRs, performer RPM,700DP, equal length shorties, stainless EXH ,T-5,Hurst pro-billet, KC clutch, 8.8/ 4.10s, line-lok, bla ,bla, bla.
71 COMET/289,351w heads, 12.5 TRWs, 750DP, Liberty TL, 9"/6.00s, 11.9x @112 , bla,bla,bla.

Never shoot your mouth off, unless your brain is loaded! ....I may get older, but I'll never grow up!....If you're not laughing, you're not living!  :laughing:

PSA: Firewall ripped apart by clutch cable!!!

Reply #8 –
Yeah the title does make it seem like my clutch grenaded doesn't it :rollin:  And now that it's mentioned I do remember seeing that somewhere about reduced force needed, I of course didn't believe that, made no sense but I guess that's also accomplished? lol
 
Which is definitely disastrous when it happens. But on the subject of the quadrant installation the MM unit I bought has those washers...maybe the Steeda one did but the guy sure didn't use them. From just eyeballing it though, side to side there doesn't seem to be much room for it to move anyway so as to rub the cable in that direction of pull, but the increased radius is killer, totally deflected angle, it should be pulled straight ahead, perpendicular to the firewall.
1987 20th Anniversary Cougar, 302 "5.0" GT-40 heads (F3ZE '93 Cobra) and TMoss Ported H.O. intake, H.O. camshaft
2.5" Duals, no cats, Flowmaster 40s, Richmond 3.73s w/ Trac-Lok, maxed out Baumann shift kit, 3000 RPM Dirty Dog non-lock TC
Aside from the Mustang crinkle headers, still looks like it's only 150 HP...
1988 Black XR7 Trick Flow top end, Tremec 3550
1988 Black XR7 Procharger P600B intercooled, Edelbrock Performer non-RPM heads, GT40 intake AOD, 13 PSI @5000 RPM. 93 octane

PSA: Firewall ripped apart by clutch cable!!!

Reply #9 –
Aod ftw! ;)
88 Thunderbird LX: 306, Edelbrock Performer heads, Comp 266HR cam, Edelbrock Performer RPM intake, bunch of other stuff.

PSA: Firewall ripped apart by clutch cable!!!

Reply #10 –
Quote from: thunderjet302;378758
Aod ftw! ;)



.....real cars have 3 pedals!  :shakeass:......LOL
84 COUGAR/90 HO, 1.7RRs, performer RPM,700DP, equal length shorties, stainless EXH ,T-5,Hurst pro-billet, KC clutch, 8.8/ 4.10s, line-lok, bla ,bla, bla.
71 COMET/289,351w heads, 12.5 TRWs, 750DP, Liberty TL, 9"/6.00s, 11.9x @112 , bla,bla,bla.

Never shoot your mouth off, unless your brain is loaded! ....I may get older, but I'll never grow up!....If you're not laughing, you're not living!  :laughing:

PSA: Firewall ripped apart by clutch cable!!!

Reply #11 –
Quote from: thunderjet302;378758
Aod ftw! ;)

You probably guessed that it's got me muttering angrily to myself about the trans swap having been done in the first place hahahaha. Can't wait to have the red car back. The 5 speed is fun, I have to give it that.
1987 20th Anniversary Cougar, 302 "5.0" GT-40 heads (F3ZE '93 Cobra) and TMoss Ported H.O. intake, H.O. camshaft
2.5" Duals, no cats, Flowmaster 40s, Richmond 3.73s w/ Trac-Lok, maxed out Baumann shift kit, 3000 RPM Dirty Dog non-lock TC
Aside from the Mustang crinkle headers, still looks like it's only 150 HP...
1988 Black XR7 Trick Flow top end, Tremec 3550
1988 Black XR7 Procharger P600B intercooled, Edelbrock Performer non-RPM heads, GT40 intake AOD, 13 PSI @5000 RPM. 93 octane

PSA: Firewall ripped apart by clutch cable!!!

Reply #12 –
Quote from: ZondaC12;378769
You probably guessed that it's got me muttering angrily to myself about the trans swap having been done in the first place hahahaha. Can't wait to have the red car back. The 5 speed is fun, I have to give it that.

Swap an AOD back in!
88 Thunderbird LX: 306, Edelbrock Performer heads, Comp 266HR cam, Edelbrock Performer RPM intake, bunch of other stuff.

PSA: Firewall ripped apart by clutch cable!!!

Reply #13 –
*whiny voice* Then I gotta get a column handle and linkage or floor and cable etc change out the dash if I get column which if I DONT then I need a new column cover because it has the hole for the column shifter...eehhhhh...wahhhhhh LOL. Then it wont weigh just 3400 pounds it'll be more like 35 and I'll whine about that too haha. The same guy doing the red car will probably take care of this. If he doesn't kick my ass for asking haha. This is two winters in a row he hasn't gotten to work on his 65 falcon, so I want him to be able to do that as well. But whenever it happens, he'll help me bomb-proof the firewall.
1987 20th Anniversary Cougar, 302 "5.0" GT-40 heads (F3ZE '93 Cobra) and TMoss Ported H.O. intake, H.O. camshaft
2.5" Duals, no cats, Flowmaster 40s, Richmond 3.73s w/ Trac-Lok, maxed out Baumann shift kit, 3000 RPM Dirty Dog non-lock TC
Aside from the Mustang crinkle headers, still looks like it's only 150 HP...
1988 Black XR7 Trick Flow top end, Tremec 3550
1988 Black XR7 Procharger P600B intercooled, Edelbrock Performer non-RPM heads, GT40 intake AOD, 13 PSI @5000 RPM. 93 octane

PSA: Firewall ripped apart by clutch cable!!!

Reply #14 –
Thanks for the heads up; I've never heard of this happening before.
Matt
1984 Thunderbird - 89 302 HO, GT40 heads w/ Trick Flow springs, E303 cam, Edelbrock Performer 289 intake and 600 cfm 4bbl, Mustang headers, Jegs o/r H pipe, Dynomax lers, Mustang AOD and shifter, Mustang 8.8 w/ 3.73s, 3G alternator, Mustang front and rear sway bars, KYB SN-95 front struts and shocks, and 11" front brakes.

1988 Mustang GT - GT40 heads, Explorer intake, 70mm throttle body, 70mm MAF, Crane 1.7 rrs, E303 cam, Kirban Kwik shifter w/ Pro 5.0 deluxe handle, aluminum clutch quadrant and firewall adjuster, o/r h pipe, Dynomax lers, 3G alternator, aluminum radiator, and 3.27 gears.
 
1986 Cougar 5.0, 1989 Mark VII LSC 5 speed, 1980 Mercury Zephyr 4 door (sold)