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-   -   Clutch Pedal Linkage Fix (http://www.wranglerforum.com/f210/clutch-pedal-linkage-fix-178371.html)

99er 08-05-2012 01:21 PM

Clutch Pedal Linkage Fix
 
The clutch pedal linkage on my 99 TJ broke and my clutch pedal went limp to the floor. The clutch pedal is attached to the master cylinder rod using a little plastic basket clip. The clip does two things. It holds the rod on and it acts as a bushing between the metal rod and the stud on the pedal that slips into the rod.

I searched the forum and found a temporary fix using a 7/16 e-clip to hold the rod onto the clutch pedal. The problem is that itís metal against metal and sloppy. The clutch cylinder rod started to wear down. I went to the hardware store and bought a few inches of ĹĒ nylon tubing in the plumbing section of the store. It was a little too big for the oval in the clutch cylinder rod to slip over. I ground the wall thickness down using a bench grinder. I then used a couple washers as spacers and the e-clip to secure the rod back on the stud on the pedal.The difficulty was working in an awkward location. I removed the driverís seat so I could get access to the linkage.

Hereís a link I found to this fix that helped and has pictures that does a better job explaining the repair. The title says fender flare but it does go to the clutch linkage page.
TJ Fender Flare Installation

john sherry 09-21-2012 06:07 PM

What a great easy fix!Doing that now...

99er 09-21-2012 08:40 PM

I got a little paranoid about the linkage failing again. It could lead to an accident if I could not push the clutch in while driving in traffic. So in addition to the fix I wrote above, I added two plastic wire ties to hold the linkage together as a fail safe. The ties don't hold a load, but if the e-clip fails, they would keep the pedal attached so at least I could still operate the clutch.
Maybe I'm just being overly cautious. The fix has done well for almost two months of on and off road driving.

mudmagnet63 11-22-2012 05:01 AM

I searched all over for a cure for that piece of crap plastic clip. if it wasn't such a pain to get to I would start over with this cure. Way better .

Kidbolt 02-01-2013 08:57 PM

Almost home in my 99 TJ Sahara today and my clutch pedal popped off. I knew it was not a serious clutch failure, but wondered what the hell. So, once I saw that the pivot pin was off of the clutch rod, I was under there looking for the missing c-clip that I was sure had popped off. I saw that little plastic thingy and just put it aside, not knowing that was the failed part. Couldn't imagine a plastic clip like that was what I was looking for. So thanks to the internet, and y'all - I now know the problem and the easy, better fix. I will be headed to Ace hardware tomorrow for a c-clip and some tubing. Thanks for the excellent advice!

Pipp88 02-01-2013 09:06 PM

Just want to say thanks on this fix I have this problem and did not have the solution

NoWayOut_TJ 02-02-2013 10:34 AM

2 Attachment(s)
Thanks for the heads up. I had never even heard of the problem until now. I took a look at mine and it fell apart in my hand. as you can see in the attached pics the clip is half gone and the linkage has already worn metal 2 metal. Caught it just in time.....;)

mikelab 07-10-2013 02:16 PM

Dorman pedal and shift linkage bushing kit part #14041 You can find at most autoparts stores. I comes with several different bushings. I use the black sleeve and a 7/16 e clip. Seems to work the best.

jowwo 07-20-2013 07:38 PM

Quote:

Originally Posted by mikelab (Post 3946735)
Dorman pedal and shift linkage bushing kit part #14041 You can find at most autoparts stores. I comes with several different bushings. I use the black sleeve and a 7/16 e clip. Seems to work the best.

Cool, I'm gonna have to stop by Oreillys on the way home from work in the morning. Mine is real bad.

Pete_Wheeler 09-02-2014 05:10 PM

NAPA replacement part for plastic bushing
 
it may not be a dealer part, but NAPA sells a Pedal and shift linkage bushing kit...#6151422 that looks to be the right part. Will find out tonight!

Water Dog 09-02-2014 06:17 PM

2 Attachment(s)
The dealer sells the stock bushings individually, the problem is that the part # does not show up on the computer. The name and part # for the plastic basket is: 254D Bushing Dealer Part # 4643448


When mine failed about a year ago, I found the same write up and considered doing it that way, but then figured the first one had lasted 120,000 miles and you can install a new one with no tools and without crawling under the dash...no brainer for me. I bought two, they were cheap. So far, no more issues.

giles45shop 09-02-2014 07:52 PM

Just an FYI, a decent sized zip tie (one of the ones w/ ~ 1/8" wide) will work as a a quick trail fix and will also last quite a while - I broke mine on the trail and it lasted more than a year before I remembered to replace it :)


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