Hello guys,

So last september my clutch packed it in on my EF XR6. The pressure plate collapsed, the pedal was heavy and I could no longer get it into gear.

So I had a new clutch kit / cable etc put in.

Now, I just got my car regod today and they have told me the clutch is on its way out again, and I dont doubt them. Its getting hard to get into first gear again sometimes, and the pedals a bit heavy again.

What can I do to stop this? I am paranoid the workshop will screw me over and tell me there is no warranty on the clutch, I dont wanna have to pay to have it all fixed up again.

Will simply reinforcing the firewall and/ OR pedal box solve this problem?

I have driven this car passively ever since I have owned it, never taken to the limiter. Never dumped clutch or done anything that may aid in what is happening.

Please help guys, so so sick of this...

Thanks
Ben

check the fire wall for cracking/ check the pedal box for cracking/re adjust the clutch and report back.
also what kind of clutch did you put in? standard replacement or a stronger one?
if i was you id check the above things and if the clutch is stuffed take it back,

Just inspected and there is no signs of a cracked firewall or cracked pedal box.

I believe the replacement was a standard ford clutch.

I am booked in to have it checked out on Monday. Thankfully they have assured me I most likely more then probably will not have to pay for a replacement if it has failed which is relieving.

I will be making sure they reinforce things for me too.

Still, if anyone has any other fixes / ideas please let me know, would be very much appreciated. Thanks.

i agree with bry, check the firewall and pedal box and adjust first...

unless you ride the clutch alot it shouldnt wear out that fast..
a std clutch driven properly should last up to and over 100,000 km..

how much adjustment do you have on the cable? it may just need adjusting.

Country driving, Yes.....city driving, No.

How good a job did they do when fitting the clutch?????.........Did they machine the flywheel, relube the spigot bearing, spline lube on the input shaft, clean the bellhousing of all the old debris, lube the snout for the throw-out bearing, check the snout for wear, clean and lube the clutch fork pivot points, check the clutch fork pivot wear plate and shoulder bolt for wear, check the clutch cable, check the rubber insulator on the clutch cable.....etc, etc, etc.......??????????????????
A trick I have found is to put a wide band heater hose clamp around the rubber insulator ( has a plastic cover/guide around it ) on the clutch cable assembly, and this gives back about 5mm of travel....cable travel, that is.

Id say these guys are on the money, when i bought my AU XR6 i first had to replace the clutch (went heavier duty as i like braking traction and figured this would longitivity of the clutch $600+ RPM clutch kit from memory thank god i have connections and only paid $260)...Then sure enough only a week after installing it, i had to adjust out the cable due to not being able to get any gears.. At first figured since i didn't replace the clutch cable intially the extra force from the clutch was stretching the old cable so i figured id buy another cabe and when i ran out of adjustment id replace it. Well before the cable made it that far, it pulled through the fire wall due to extra force from the upgrade. Well once again out came the wallet, $300 later (although i fear it would have cost alot more if once again had mates in workshops) Firewall repaired and reinforced.. Then the cable breaks, so changed that over(done this myself).. A couple of weeks later, started having to adjust new cable out... Then my cruise control stopped working then eventually my pedal box broke.. Once again, pull it out, re-inforce, re-install.

I guess what im trying to say in this rant is anyone who has a manual ford, if you havent already done it, re-inforce your firewall and pedal box... Trust me they ALL break eventually due to the 2mm paper thin sheet metal they call a "fire wall"... That then creates the extra force to then destroy your pedal box..

P.S. If you had a standard clutch put in, Get the thrust bearing checked out.. A mate had a thrust bearing going in his and that caused all the exact same problems i am having