Talk Morgan Forums Morgan Sports Cars Maintenance & Servicing Clutch pedal jamming

I noticed a weird problem (2007 +4) when sometimes when I depress the clutch pedal it jams hard (the pedal moves a little but not enough to operate the clutch).

It almost seems like something is caught behind the pedal, the stop is that positive. If I lift off and then re-apply it works fine. This only happens occasionally.

I have checked the pedal and it looks fine, no binding or anything obvious. I did think perhaps my foot was jamming against the tunnel or the brake pedal, but it is neither.

If the binding was in the clutch then I assume I would feel some give as it is hydraulic but the stop is almost like a piece of wood has been placed behind the pedal.

Anyone got any thoughts?

Has the return spring broken and gone unnoticed? It might occasionally work to a position where it impedes the movement?

Thanks, that was a good idea, but I checked and the spring is fine.

Might be worth ripping the assembly out and giving it a good greasing. Perhaps it has dried out or wasn’t lubricated enough in the first place? What I remember is that it is steel running on steel so if the lubrication has gone there is the potential to seize.

The assembly comes in and out quite easily.

looks like a complete strip is on the cards. My clutch pedal spring has around 4mm space between each turn of the coil, not neat like yours!

Found the problem, the spring had fatigue, when I tried to move the coils closer together it snapped into 3 pieces.

Thanks for your help Roger.

Brilliant

Tip!... When you have the new spring and you are pondering how and which way around to wind it on to the arm (beware the two springs are handed) make an experimental spring out of some soft coat hanger wire and practice first. It’s a bit of a puzzle. The new spring can only go on one way and you have one shot. If you get it wrong you can wreck the spring as it will not back wind.

Might be an idea to replace both springs while you are at it.

I think I will replace both springs (and get spares), rubbers and just might put a continuous weld on the brackets and clean them up. The welds on mine look a bit dodgy.

Update:

When I dissembled the pedal bar the pin which holds the clutch master cylinder crutch to the clutch pedal arm actuator was worn into an oval shape. The hole in the pedal arm actuator was also worn to an oval.

Thus sometimes they must lock together to cause the jam, its a good job it did not happen on the brake pedal (which in my case was fine).

I have turned a new pin on the lathe and will probably drill out the hole in the actuator arm and fit a bearing bush.

Strange that Morgan fitted internal bearing sleeves into the tubes the pedals are welded to but did not fit them to the actuator arms.

My theory on the spring fracture is that the spring coils are too loose on the tube and when the clutch is operated the spring is tightened but also twisted and that lead to fatigue.