Update time!
I was happy because I just picked up my drivers seat, which as you know from a previous post needed to be welded and repaired. I found a local upholstery shop who disassembled the seat, welded the frame, and replaced a vinyl panel where it was ripped- all for just under $400 bucks (and it looks great!) I consider this a deal because I know my limitations: trying to do this by myself, I almost certainly would have screwed it up! So to celebrate, I was out driving my car- cruising around at night (so no one can tell I have at least three different color panels on the car!), and I'm operating the clutch pedal to shift gears, when I hear a loud BANG, co-in-siding with my clutch pedal rapidly going to the floor. Hmm- this can't be good! I pull over, and confirm, no more clutch- although it feels like at first it might work, only to find it then again hits the floor, and makes a goofy ratcheting sound when it's coming back up. At least I made it to the side of the road when it broke, but dumb knee-jerk reaction was I then shut off the car.
So, I first contemplate calling a tow truck, but then after thinking for a bit and assessing the situation, I realized- it's light to no traffic, a tow truck is $$$, and if I try and still can't make it home, worst case is I gotta pay $$$ for a tow anyways* So, I put it in gear, and since I knew already my clutch interlock was never functional since I've owned the car, get it in first, confirm no traffic, run the starter, and it actually starts in first gear. I got going a little ways, then backed off the throttle, while pulling it into neutral. Then while coasting I tried best I could to rev match, and it actually went into second gear. I drove it home in second, timing two red lights just right, and being VERY careful at a stop sign that I may or may not have stopped at. Somehow I timed the garage door opener, my driveway ramp, and pulling into my garage just right- shutting the car off and hitting the brakes, I stopped in my usual spot.
At first I was really happy- I made it!!! Back in my garage! *Then I realized how f'ing stupid I was to attempt to drive the car like this, how lucky I was that I made it, and didn't screw up in traffic, or wreck my car or my house pulling into the garage. On the other side of the garage is the dining room- my wife would NOT have been happy!
Anyways, gracias a Dios, I made it.
Online research convinces me, that I've probably broken my clutch quadrant, which I was able to visually confirm was actually the stock plastic unit. At first I considered that trick looking Steeda aluminum quadrant. Then reading the fine print, I see that you have to use their special adjustable clutch cable. Then, I notice just about everyone that has one has the firewall adjuster too. Hmm.. That's funny, I never had to adjust my clutch before- and I always thought how good the clutch felt for such an aged beast too! So, quick read in my service manual, and I realize, the plastic quadrant also has a self adjuster locking pawl, and some springs too- with a non adjustable cable. The whole assembly adjusts itself (until it breaks that is!), but, mine appears to have lasted a LONG time (possibly it is the original part..) Besides, I like stock- call me corny, but it's what I like! So, I ordered a NOS quadrant assembly- came with the quadrant, pawl, new springs, new shaft, and I also ordered new bushings.. These are actually around to buy, for about the same money as buying the aluminum aftermarket stuff. Besides, how hard could this be to assemble I ask myself?
Well..... After three days, it is done... I didn't break anything... I did it right... It works (clutch actually feels REALLY good and smooth!) However, on my personal scale of 1-10 difficulty I rate this job a 12. In other words, if a 1 is considered "gravy", this job I'd consider "The whore of all whores!"
That bracket! Uhg!! If you've not done this before, and you don't want to pull the dashboard, you have to remove the Driver's seat and steering wheel, a lot of trim and things. Then, you have to essentially wedge yourself upside down under the dash. Opps! I forgot to mention, first you have to disconnect the clutch cable underneath the car! Hurray! After doing this, I think I could do it faster if I had to do it again (and God I hope I never have to do this again!!!) I figured out after removing the nuts on the brake booster inside the car with a wrench and going VERY carefully, that use of two swivels and two extensions allows for good speedy re-install with a ratchet. Really, the hardest part was getting the pedal bracket out and then back in. I digress. I replaced the clutch cable too for good measure- I figured, I have to essentially R&R it anyways, why not replace it while I'm there. The old one looked fine (although kinda gooey.. Someone must of lubed the clutch cable at some point- I've never lubed these cables personally, and am not planning on lubing the new one). Oh well, now I have a spare one if the new one breaks.
Here's the broken quadrant when I got it out- it was stripped:
Here's the car, mid-repair: (Of special note, please see the cardboard "pad" that I tried to use to prevent me from jabbing myself with that seat stud. I poked the stud through one side of the cardboard, and folded the cardboard over the top of it. This worked great, until I put my weight on it, and it poked through the top of the cardboard! @#$%%^!!!! At least it didn't cut me! It would have been a shame to get blood all over that new carpet!)
Here's my pile of old parts, and the pedal bracket- which the OCD side of me just had to clean before re-assembly! PS: Did I mention how hard it was to snake that big freakin bracket out and back into the car, while upside down, while wedged under the dash, with a seat bolt stud repeatedly poking you, and a heavy steering column is nestled on your chest?!? At least I had some good tunes on the radio!
Oh- see the clutch interlock switch? A previous owner had disconnected it from the clutch lever, and zip tied it in the
clutch fully depressed" condition. I might keep a zip tie in my glove box if I ever need to circumvent this on the road again!
AND, here's the car all back together (and with the original seats, driver's seat just rebuilt and no longer leaning back on one side):
As I mentioned, so far so good with the clutch quadrant, new bushings, new clutch cable, etc. And, now the clutch interlock switch is working. Brake lights and horn work too (they worked before, but had to be disconnected during the repair- so I'm glad these work still!)
I gotta say, after doing this once, I think I'd be faster if I ever had to do this again. BUT, I cannot imagine a guy at a shop trying to do this with a customer's car, and planning on making any money on this job. It must have taken me perhaps 5 or 6 hours actual working time, spread across the three days- maybe a bit more... Granted, I'm not doing this stuff every day, and I was cleaning things as I was going, and being anal retentive, etc., which I imagine a pro mechanic would not waste time cleaning and primping. And, they have a lift, which would make the clutch cable part easier (and maybe would allow for work on the quadrant standing up and not wedged under the dash?) I can not even fathom what the "book time" would be for this job. Overall, despite my complaining, this was a pretty enjoyable repair- in that I'm happy I used the self adjuster (if it soon breaks though, I'm using the Steeda aluminum one for sure!) and I've got a warm and fuzzy now that it's done. Original matching seats in this bad boy now too- they match the back seat which of course was original. I'm pretty much done in the interior now.
Time to focus on body work and paint..
Jason