Clutch Preload Issue - too much preload on throwout bearinw/replacement clutch cable

[Gumball]

I chronicled my recent broken clutch cable here..... http://thefactoryfiveforum.com/showthread.php?4982-How-to-install-vintage-Ford-degas-tank-on-small-block-aka-overflow-or-fill-tank .... and posted a comparison pic between the OEM-style cables and the aftermarket ones. I also mentioned that I ordered the OEM style from Maximum Motorsports.

Well, the Maximum Motorsports OEM-style cables didn't work out too well, as the sheathing and cables were nearly a foot longer than the one I had on the car and the two Ford Motorsport replacements I have on the shelf. So, I ended up using one of the Ford Motorsport cables (from Forte's).

But, there is a bit of a problem - at least in my opinion. In order to get the new cable to fit, I had to lever the clutch fork forward nearly an inch, then let it spring back when the cable end was in the receiver hole on the end of the fork. But, it didn't return far enough to give the cable any slack and there is a fair amount of pre-load on the throwout bearing against the clutch fingers/springs now. I have the firewall adjuster all the way in towards the firewall, so there's no way to get any more slack.

Does anyone else have that problem using the Ford Motorsports cables? Is this normal? I would think that some free-play before engaging the throwout bearing is needed or I'm going to burn that thing out quickly.

The only thing I can think is that I'm using a '94 bellhousing, which with the '95 was a two-year only version and it's slightly longer / deeper than other years for the 5.0 / 302 pushrod engine. Could that be the problem? If so, I may need to see if there is a specific part number for the '94 / '95 cable.

Hopefully Mike Forte and Gordon Levy will chime in, too!!!

[Gumball]

Two alternatives came to mind while simmering on this and enjoying dinner with the family..... 1) I'll have to check to make sure that I'm using the right hook on the quadrant - it's hard to see up under there as I don't have an access panel from the engine compartment, so I'm working upside-down and reaching up into the hidden area above the footwell. 2) I ordered a couple of alternative adjustable cables with the threaded adjuster at the clutch fork end (one from Ford Performance and the other from BBK) - this may solve the "too short" problem.

[frankeeski]

Chris, when you are using the firewall adjuster you need to chuck the rubber bushing. Could this be the extra inch you're looking for?

[steno]

I have a ford cable with the adjuster in all the way, and the rubber removed. Same issue with a 93 bell housing. Was wondering the same thing!

[CraigS]

Been a while since I have looked at a 94 hell housing but I think you have the right idea. I have recently looked at a 302 and 351 block plate and they both have a hole for the clutch cable to pass through. Seems to me the cable sleeve is going to locate at the front edge of the bell, so a 94 bell needs a longer cable. I don't know this but it sure makes sense.

[BEAR-AvHistory]

Two alternatives came to mind while simmering on this and enjoying dinner with the family..... 1) I'll have to check to make sure that I'm using the right hook on the quadrant - it's hard to see up under there as I don't have an access panel from the engine compartment, so I'm working upside-down and reaching up into the hidden area above the footwell. 2) I ordered a couple of alternative adjustable cables with the threaded adjuster at the clutch fork end (one from Ford Performance and the other from BBK) - this may solve the "too short" problem.

I have a pair of cables in the draw I got from Forte about a year ago on a 2-4 sale. How can you visually tell if its a FORD cable or aftermarket?

[CraigS]

Re-thinking this. The clutch would be the same for a 93 as a 94 so the pressure plate fingers would be the same distance from the block plate. So thinking the extra bell housing length would not affect cable length. Weird Rock Auto shows 5-6 different brand cables. 2 have the same part number for a 93 as a 95. 3 have different numbers. But a couple show the length and the 95 is listed as 61.xx and the 93 as 59.xx inches. Weird.

[Gumball]

I gave up on the fixed length cable - sorry to hear Sten has the same issue, but glad it's not just me. I agree with Craig that while the bellhousing is different, that shouldn't be the issue here. The stock rubber firewall donut is off the cable and with my firewall adjuster knob all the way in, the replacement cable is just too short.

The BBK cable that I used originally had the short threaded rod adjustable end for installation on the clutch fork. The issue was that it was following the arc of the clutch fork and it stressed the cable right where it's swagged into the end until it failed. Summit Racing sells a Ford Motorsport version with the same threaded rod adjustable end, so I'm going to do a little modification and make it operate like the fixed length, with a radiused end by machining one of the lock nuts in my lathe (effectively making an open ended acorn nut, but with the right radius to fit into the cup on the clutch fork).

Here's my first attempt at making the fittings using the broken cable end...... more pics to come when I get the new cable and get it installed.

http://i845.photobucket.com/albums/ab15/CCRsAC/IMG_20160703_141137854_zpskmuurqxm.jpg (http://s845.photobucket.com/user/CCRsAC/media/IMG_20160703_141137854_zpskmuurqxm.jpg.html)