Broken clutch pedal

ac_

zombicon
Original poster
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Joined
Jun 15, 2017
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4,699
Location
AZ, United States
So I was leaving yesterday to go to work on the old house, and I pulled out of the garage into the sunlight, but then decided I would backup into the shade. I started to backup, then all of a sudden the clutch pedal went straight to the floor, and the Jeep lit up the tires towards the house. All I could think of quickly because I was in shock was to push the brakes with both feet till the engine died. Left some nice marks in the driveway.

Anyway I checked underneath for leaks, and loose parts, then slowly went backwards to the pedal where I found the rod fell off of the clutch pedal. I found a broken plastic bushing. I quickly jumped in my truck, and ran down to the dealer where they actually had a new one for 5 bucks. It looked like a .05 cent part, but whatever they had one. when I got back home I found the place that the bushing goes over is wore down to the end. Like another couple of pumps and it will probably actually break clean off of the pedal. I was really shocked at the horrible engineering of this connection.

I am posting this to the 5sp Jeep owners especially the old ones to check this connection on your clutch every now and again. Maybe even replace that bushing and double check the place where it sits. It is really dangerous if you are on the trail and the clutch master rod breaks off.

Now maybe mine is rare that the place where the bushing sits is wore out and probably broke my bushing, but still it is worth while checking yours out.
@starkey480 Chris (Chandler Jeep guy) had a new pedal assembly for 35 bucks. It has some weirdness around the brake pedal, but for 35 bucks it is worth it. Now I need to pull my pedal assembly out and take them apart and replace my clutch pedal (Depending on what is actually wrong with the brake pedal on the used part) The place where the clutch rod goes is in good shape on the used part so it might just be some weirdness with mine that it is extra warn. Maybe I should replace the rod that goes into the master too? I will check it all out when I get the pedals out.

If anybody has any tricks on how to get this pedal assembly out I would appreciate the feed back.

Cheers,
 
Something similar happened to me a while back while backing out of a parking lot. Plastic retainer holding the clutch slave cylinder rod to the clutch pedal gave up the ghost. Had to pull the clutch neutral safety fuse to get home. Fix was a new clutch slave cylinder.
 
Yeah the part that the bushing rides on on the pedal is so worn it almost broke completely off. It finally broke the bushing, and I just checked the master, and the rod that goes around the bushing is all worn out also. it is all bad. I found a new pedal assembly locally this weekend, and just ordered a new master and slave from Rock Auto, So I will start disassembly tomorrow starting with the removal of the front seat. arg Also in the middle of installing onboard air. I actually got that done, just need to drill the hole in the bumper and install my quick disconnect, and that project will be finished.

Worst timing ever. I have a kubernetes Raspberry pi cluster to build simultaneously. So I will be installing ubuntu server on sd cards while tearing down my Jeep. No rest for the wicked. haha. I am missing my shop at my house right now.
 
Following. The clutch pedal rod on my 05 Sport will pull straight out and leave a floppy pedal. Dealer quoted me $200 something and I said uh no.
So I found a fix. If your pedal isn't actually broken like mine you can get a small nylon washer that can slip over your collar on your pedal then two 1/2 inch washer and a 7/16 eclip will fix your problem. The nylon washer that fits on the collar might need to be trimmed a bit for the clutch rod to fit.

tj_clu16.jpg
tj_clu15.jpg


This wont for for me because my pedal is actually broken, but if your pedal is ok looks like this would be a good solution. Lot less than 2 hundred bucks

Reference here:
http://www.southernhighrollers.com/tech/articles/tj_clutch.htm
 
Ok so tonight I did some multitasking. I am downloading my ubuntu server for pi and I pulled out the pedal assembly

IMG-2117.JPG


Here is the new pedal

IMG-2114.JPG


Here is my broken one, Can you tell the difference?

IMG-2119.JPG


So I am hoping to get the pedal assembly back in tomorrow after work. Still waiting for the new Mopar hydraulics to come from Rock Auto. but would really like to get the pedals back in and ready to go before they get here.
 
Got my new clutch pedal installed on the assembly, and set back in. I bolted the brake booster back on loosely, still waiting on the new Mopar hydraulics to show up before I can finish.
 
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UPDATE: Finally got time to finish up!

Breakdown:
I removed the pedal assembly, and took the pedal assembly apart, and replaced the clutch pedal. I checked the clutch master and it was also worn out where it connects to the pedal so I replaced the clutch hydraulics with now Mopar parts, and then put the pedal assy. back in tonight. I am happy to say the zombicon is back on the road again. Watch out Arizona!!

IMG-2121.JPG
 
So I was leaving yesterday to go to work on the old house, and I pulled out of the garage into the sunlight, but then decided I would backup into the shade. I started to backup, then all of a sudden the clutch pedal went straight to the floor, and the Jeep lit up the tires towards the house. All I could think of quickly because I was in shock was to push the brakes with both feet till the engine died. Left some nice marks in the driveway.

Anyway I checked underneath for leaks, and loose parts, then slowly went backwards to the pedal where I found the rod fell off of the clutch pedal. I found a broken plastic bushing. I quickly jumped in my truck, and ran down to the dealer where they actually had a new one for 5 bucks. It looked like a .05 cent part, but whatever they had one. when I got back home I found the place that the bushing goes over is wore down to the end. Like another couple of pumps and it will probably actually break clean off of the pedal. I was really shocked at the horrible engineering of this connection.

I am posting this to the 5sp Jeep owners especially the old ones to check this connection on your clutch every now and again. Maybe even replace that bushing and double check the place where it sits. It is really dangerous if you are on the trail and the clutch master rod breaks off.

Now maybe mine is rare that the place where the bushing sits is wore out and probably broke my bushing, but still it is worth while checking yours out.
@starkey480 Chris (Chandler Jeep guy) had a new pedal assembly for 35 bucks. It has some weirdness around the brake pedal, but for 35 bucks it is worth it. Now I need to pull my pedal assembly out and take them apart and replace my clutch pedal (Depending on what is actually wrong with the brake pedal on the used part) The place where the clutch rod goes is in good shape on the used part so it might just be some weirdness with mine that it is extra warn. Maybe I should replace the rod that goes into the master too? I will check it all out when I get the pedals out.

If anybody has any tricks on how to get this pedal assembly out I would appreciate the feed back.

Cheers,
This happened to me up past Presley Lake on a US Forest Road designated 4x4 Road. The switch that goes between master cylinder and peddle broke. The rod came out to master cylinder too. Clutch peddle arm just hanging there. My friend with me knew right away what happened. Took a long time to jerry rig it so we could get out of there (about 12 miles off Hwy 22). I was able to nurse it home. We replaced the entire master/slave cylinder set up and put in a new switch. A week later the peddle broke again. TGhe peddle was firm until almost the end then just banged into fire wall, as if it lost pressure at end. This kept happening until finally I heard a crunch sound and there is goes hanging like a limp arm. But his time it seems all was intact. I felt around on top of peddle arm and found a top hole that was plugged from my side. I found the part that goes in and it seemed to snap into place but not sure what that part was. Haven't done any thing yet as I can not find a picture of what that part i snapped in there is. Ideas?
 
I think I may know.
On my Jeep up on the clutch pedal, where the master cylinder rod connects to the pedal completely broke off. I had to replace my pedal completely, but before I replaced it I didn't really look at it close enough, and there is a plastic insert that snaps the rod to the pedal. So basically the rod has a circle on the end and a little plastic piece snaps in the hole and then it all snaps on the pedal if you haven't lost the nub.

The plastic piece is like 5 bucks at the dealer. Once I found out that my pedal broke I decided to replace all of the hydraulics with Mopar closed set, and it also came with that plastic piece already snapped into the rod of the master cylinder.

But all of that said if you keep breaking the plastic piece check your pedal. I mean get up in there with a light and a camera or whatever, You do not want that to happen when you are out cliff hanging, or at any time really. Make sure you pedal is in good shape!
 
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Ok so tonight I did some multitasking. I am downloading my ubuntu server for pi and I pulled out the pedal assembly

View attachment 123558

Here is the new pedal

View attachment 123559

Here is my broken one, Can you tell the difference?

View attachment 123560

So I am hoping to get the pedal assembly back in tomorrow after work. Still waiting for the new Mopar hydraulics to come from Rock Auto. but would really like to get the pedals back in and ready to go before they get here.
How did you get this off? I have all the nuts off, but it’s binding up on the studs.
 
I'm curious what brand of master/slave cylinder you went with? I'm in your exact situation, I've got to replace the pedal and everything. On my OEM master cylinder pushrod, the end is made out of metal but on most aftermarket options they're plastic. If the metal one wore out I am wondering how bad the plastic options will be...
 
great post, i'm a new 2004 jeep wrangler owner. I'm having this issue and will be buying that $5 part, but also have an issue with the plunger that goes through the firewall to the master cylinder: it pops out once in a while. What can i do to ensure that it says in? is there a cotter pin or something i can install?
 
So I was leaving yesterday to go to work on the old house, and I pulled out of the garage into the sunlight, but then decided I would backup into the shade. I started to backup, then all of a sudden the clutch pedal went straight to the floor, and the Jeep lit up the tires towards the house. All I could think of quickly because I was in shock was to push the brakes with both feet till the engine died. Left some nice marks in the driveway.

Anyway I checked underneath for leaks, and loose parts, then slowly went backwards to the pedal where I found the rod fell off of the clutch pedal. I found a broken plastic bushing. I quickly jumped in my truck, and ran down to the dealer where they actually had a new one for 5 bucks. It looked like a .05 cent part, but whatever they had one. when I got back home I found the place that the bushing goes over is wore down to the end. Like another couple of pumps and it will probably actually break clean off of the pedal. I was really shocked at the horrible engineering of this connection.

I am posting this to the 5sp Jeep owners especially the old ones to check this connection on your clutch every now and again. Maybe even replace that bushing and double check the place where it sits. It is really dangerous if you are on the trail and the clutch master rod breaks off.

Now maybe mine is rare that the place where the bushing sits is wore out and probably broke my bushing, but still it is worth while checking yours out.
@starkey480 Chris (Chandler Jeep guy) had a new pedal assembly for 35 bucks. It has some weirdness around the brake pedal, but for 35 bucks it is worth it. Now I need to pull my pedal assembly out and take them apart and replace my clutch pedal (Depending on what is actually wrong with the brake pedal on the used part) The place where the clutch rod goes is in good shape on the used part so it might just be some weirdness with mine that it is extra warn. Maybe I should replace the rod that goes into the master too? I will check it all out when I get the pedals out.

If anybody has any tricks on how to get this pedal assembly out I would appreciate the feed back.

Cheers,

Odd that you should mention this because I’m having similar problems myself it’s been driving me literally crazy it started like with the car, not starting, which ended up being a new starter and prior to that maybe two years before that we had a clutch put in a new clutch put in and then it was like I don’t know Winck 33 weeks went by and then just sporadically. The car would just not start sometimes, and then like two hours would go by and I would go and check it and if it was not the alternator I went through I mean trust me I’ve been doing with this for months and I just can’t and then today my friend took out that fuse that you’re just talking about and the rod and it started up and I used it yesterday but then of course, today I get in and nothing so I am at a loss too because I’ve never experienced this before ever and I’ve driven manuals pretty much since forever and I mean I can put I mean I can move around the clutch and one time it even started without me even pushing the clutch, so please if you hear anything advise
 
Odd that you should mention this because I’m having similar problems myself it’s been driving me literally crazy it started like with the car, not starting, which ended up being a new starter and prior to that maybe two years before that we had a clutch put in a new clutch put in and then it was like I don’t know Winck 33 weeks went by and then just sporadically. The car would just not start sometimes, and then like two hours would go by and I would go and check it and if it was not the alternator I went through I mean trust me I’ve been doing with this for months and I just can’t and then today my friend took out that fuse that you’re just talking about and the rod and it started up and I used it yesterday but then of course, today I get in and nothing so I am at a loss too because I’ve never experienced this before ever and I’ve driven manuals pretty much since forever and I mean I can put I mean I can move around the clutch and one time it even started without me even pushing the clutch, so please if you hear anything advise

Welcome to WTF. ;)
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