Ive got my dash out for the climate control conversion and while I was at I thought I may as well pull the pedal box out and get it strengthened because the pedal had developed an interesting angle on it.
It was lucky I had as it had major cracks in it and the shaft was quite bent.
What I also noticed was that the cable had cut through its plastic and metal outer 'tubing' and had started to cut through the firewall.
I had hoped it was because of the angle of the pedal due to the bent shaft was causing this, but with the fixed pedal box it looks like it will keep doing it.
I will put a new cable in there but I imagine it will eventually do it again.

The only easy way I see fixing this is to lower the shaft on the pedal that pulls the cable an inch or so which will reduce the angle at which the cable is pulled through the firewall, although this may make the clutch feel even heavier than it already is due to reducing the pivot length.

My only other idea is to cut out the offending piece of the firewall around the clutch tubing (which has been welded before) and weld in a piece cut out of my wreck auto Fairmont (strengthened of course) in there at a slightly higher location. Only problem with this is that I cant weld and I dont think I could be f**k.

I know the pedal box breaking is common but how common is the cable cutting the firewall?

A common problem with the manuals, i think Ford had a fix for this, but you just need to cut some plate, weld it in, to strenghten that area, some on here have done it.

I just welded it back up...we'll see how long that takes. If not, I'll just weld a 6mm steel plate onto it.

their is a part u can buy from ford for this goes back to cp? i think days

f**k knows what it is called

My car is in the workshop at the moment for the same problem.

Gettin firewall strengthened and welded and pedal pox strengthened.

From everyone I spoke to, It's extremely common and not real cheap to b fixed professionally.

I would have given it a go but with 6-7 day weeks was easier to get it done.

Round about price for firewall and pedal box is $700ish

don't no bout the pedal box, but i've had 2 firewalls go, one in my EA s pack and one in my ef gli, had a plate drilled and welded onto the firewall (engine bay side) cost me $200, painted it myself worked like a charm.
NOw just waiting for my EF2 XR6 to develope the same problem.
Hope this helps, the firewall is a simple fix.

I'd be doing it before the firewall gives. Means you can do it when you want.