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Very Heavy clutch pedal #576666
15/05/19 01:39 PM
15/05/19 01:39 PM
Joined: Jun 2012
Posts: 14
guernsey CI
S
sarnia Offline OP
New to Talk Morgan
sarnia  Offline OP
New to Talk Morgan
S

Joined: Jun 2012
Posts: 14
guernsey CI
I have a 1994 Morgan 4/4 with 1800 Ford Zetec with milage of 21000.
It has always had a very hard to press clutch pedal, but lately seems to be even harder. ( It may be my age). The clutch is cable not hydraulic, I have lubricated the pedal box and wonder if it could be the cable being worn. If I don't fully press the clutch pedal sometimes I can crunch the gears. Any advise would be appreciated. Regards Sarnia

Re: Very Heavy clutch pedal [Re: sarnia] #576671
15/05/19 02:18 PM
15/05/19 02:18 PM
Joined: Aug 2015
Posts: 30
Luxembourg
M
mich Offline
Just Getting Started
mich  Offline
Just Getting Started
M

Joined: Aug 2015
Posts: 30
Luxembourg
Hi Sarnia,

I had exactly the same issue when I bought mine a few years ago. I went for the pedal box, over-greased every possible part of the system to zero effect. In my case it all came down to an originally badly guided clutch cable of more than a a meter which went all the way from the drivers side (left on my car) passing far in front of the sump to the bellhouse clutch fitment on the other side. That long and wobbly cable eventually wore out until the clutch pedal showed the symptoms you describe. I went through some very poor attempts by a local garage to fix it- resulting in a general overhaul of the gearbox, a new clutch set a.s.o. I learned quite something about Morgan mechanics over a few months.
In hindsight a new, shorter, properly guided clutch cable would have been the end of all trouble. My new shorter cable now runs behind the sump. Clutch works perfectly.

Cheers, Mich

Last edited by mich; 15/05/19 02:20 PM.

4/4 1996 1.8 ZETEC It has Swivel Pivots and an amazing Umbrella Holder!
Re: Very Heavy clutch pedal [Re: sarnia] #576676
15/05/19 03:16 PM
15/05/19 03:16 PM
Joined: Apr 2008
Posts: 7,617
Gloucestershire, UK
Hamwich Online content
Talk Morgan Guru
Hamwich  Online Content
Talk Morgan Guru

Joined: Apr 2008
Posts: 7,617
Gloucestershire, UK
Here's what I think may be happening.

The cars of this era that have a cable-operated clutch use a bell-crank type arrangement to transfer the thrust of the clutch push rod to the pull on the cable to operate the clutch. It is mounted low down on the forward face of the engine bulkhead just next to the brake master cylinder.

The bell crank comprises two arms arranged at 90 degrees to each other, the arms are brazed to the ends of a tube. Over time, the brazing weakens and the angle between the two arms reduces from 90 degrees. This has the effect of reducing both the mechanical advantage and the length of throw, causing the clutch to become heavier and more difficult to disengage.

The cure is to remove the crank, realign the arms to 90 degrees, and weld in a bit more stiffening.

The picture below is of my car at Kevin Vernon's, showing the beefed-up version that he did for my car when he put the new chassis on. The finger pointing at it belongs to none other than SpannerJuggler.



Tim H.
1986 4/4 VVTi Sport, 2002 LR Defender, 1957 R4 CV, 2005 Ferrari Vipar
Re: Very Heavy clutch pedal [Re: Hamwich] #576680
15/05/19 03:45 PM
15/05/19 03:45 PM
Joined: Sep 2014
Posts: 1,397
London
MOG 615 Offline
Has a lot to Say!
MOG 615  Offline
Has a lot to Say!

Joined: Sep 2014
Posts: 1,397
London
Originally Posted By Hamwich
The finger pointing at it belongs to none other than SpannerJuggler.



Thought I recognised those dainty fingers . Looks like a good mod from Kevin there Tim


Andy G
1999 +8 , Indigo Blue.
Ex-John McKecknie/Mike Duncan 1955 +4 racer.
Re: Very Heavy clutch pedal [Re: sarnia] #576683
15/05/19 04:00 PM
15/05/19 04:00 PM
Joined: Dec 2011
Posts: 1,723
Seattle, USA
B
Button Offline
Talk Morgan Enthusiast
Button  Offline
Talk Morgan Enthusiast
B

Joined: Dec 2011
Posts: 1,723
Seattle, USA
Rather than engineer a method of clutch release I opted for an internal slave system for My +8 Bitsa and ZETEC powered DHC. The downside of this is I must pull the engine/trans if I have problems with the slave. The upside is an easy design and by changing the size of the clutch MC I can very the effort required. Another downside may be cost???


Button
Re: Very Heavy clutch pedal [Re: Hamwich] #576685
15/05/19 04:40 PM
15/05/19 04:40 PM
Joined: May 2014
Posts: 2,573
S
SteveT Offline
Talk Morgan Expert
SteveT  Offline
Talk Morgan Expert
S

Joined: May 2014
Posts: 2,573
Those nails look far too clean to me..

Re: Very Heavy clutch pedal [Re: sarnia] #576686
15/05/19 04:44 PM
15/05/19 04:44 PM
Joined: Oct 2006
Posts: 2,358
C
cerealsurfer Offline
Talk Morgan Expert
cerealsurfer  Offline
Talk Morgan Expert
C

Joined: Oct 2006
Posts: 2,358
Seconded on the swap to Hydraulic - Retroford do a kit for T5 box and also Type9/Rocket box.

They may be able to supply a kit for you:

http://www.retro-ford.co.uk/shop/content/type-9-rocket-hydraulic-clutch-release-bearing-kit-bc002





Re: Very Heavy clutch pedal [Re: mich] #576689
15/05/19 04:56 PM
15/05/19 04:56 PM
Joined: Jun 2012
Posts: 14
guernsey CI
S
sarnia Offline OP
New to Talk Morgan
sarnia  Offline OP
New to Talk Morgan
S

Joined: Jun 2012
Posts: 14
guernsey CI
thankyou Mich i will try and purchase a shorter cable ,if i can find a supplier .thanks again. Sarnia

Re: Very Heavy clutch pedal [Re: MOG 615] #576696
15/05/19 05:32 PM
15/05/19 05:32 PM
Joined: Apr 2008
Posts: 7,617
Gloucestershire, UK
Hamwich Online content
Talk Morgan Guru
Hamwich  Online Content
Talk Morgan Guru

Joined: Apr 2008
Posts: 7,617
Gloucestershire, UK
Originally Posted By MOG 615
Originally Posted By Hamwich
The finger pointing at it belongs to none other than SpannerJuggler.



Thought I recognised those dainty fingers . Looks like a good mod from Kevin there Tim


I've just remembered - that's actually my hand, Colin was taking the pictures. I was far too excited to remember to take any photographs myself.

Last edited by Hamwich; 15/05/19 05:32 PM.

Tim H.
1986 4/4 VVTi Sport, 2002 LR Defender, 1957 R4 CV, 2005 Ferrari Vipar
Re: Very Heavy clutch pedal [Re: sarnia] #576724
15/05/19 07:28 PM
15/05/19 07:28 PM
Joined: Jan 2012
Posts: 3,650
UK (up north)
Dean-Royal Offline
Talk Morgan Addict
Dean-Royal  Offline
Talk Morgan Addict

Joined: Jan 2012
Posts: 3,650
UK (up north)
Clutch Diaphram plate hardened, replace full Clutch Kit


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