tracker broken clutch pedal! - Off-Road Forums & Discussion Groups
Suzuki GEO All Discussion of all things, Suzuki and GEO

 
LinkBack Thread Tools Display Modes
post #1 of (permalink) Old 12-20-2004, 10:01 AM
ridgerunner99
Guest
 
Posts: n/a
tracker broken clutch pedal!

I have a 96 geo tracker with a five speed. My clutch pedal engagement heigth began to drop and consequently, shifting became difficult. I adjusted it back up at the cable adjustment on the clutch fork at the bell housing and regained proper shifting. I suspected that the clutch cable was frayed in the housing and "stretching" so i replaced it also. However, the pedal continued to drop and finally, this adjustment made no difference and I had to shift with NO clutch. The clutch pedal arm is welded to a rod that has the cable attachment bolted on the other end of the rod. After much detective work and even replacing the clutch assembly (CHILDREN DON'T TRY THIS AT HOME)I discovered that the weld holding the pedal to the rod was defective and had finally broken in the end. I've removed the assembly (a real nightmare because you have to take out the computers and then you have very little room to work) and re-welded the pedal but it broke again within a few miles. Has anyone had this problem??? Is there some fix out there other than welding the pedal back to the rod? Can a hydaulic system be retrofitted without much work?

HELP!!!!!!
Sponsored Links
Advertisement
 
post #2 of (permalink) Old 12-20-2004, 04:02 PM
Addict
 
Join Date: Apr 2002
Location: Carrollton, Georgia
Posts: 576
Thanks: 0
Thanked 0 Times in 0 Posts
 
Re: tracker broken clutch pedal!

I dont know what it would take to convert it over to the hydr type clutch, but I have a 99 here with the hydr clutch. All the parts are still on it. You may have to change the arm that works the throwout bearing. Not sure. But I have the transmission also that can go with it.
ka4yqi is offline  
post #3 of (permalink) Old 12-20-2004, 04:03 PM
Way Outta Control
 
Join Date: Sep 1999
Location: usa
Posts: 10,815
Thanks: 0
Thanked 1 Time in 1 Post
 
Re: tracker broken clutch pedal!

""""and re-welded the pedal but it broke again within a few miles.""""

Sounds like it wasn't really re-welded, just looked like it.

I used a press to break the weld on mine so I could re-position it -- I'd pushed the floor up to clear the 35's, had to modify the pedal to get the travel needed.

The "re-weld" has held fine. It takes quite a bit of heat since it's thick material, the 110v toy welders won't do it.
RRich is offline  
Sponsored Links
Advertisement
 
post #4 of (permalink) Old 12-21-2004, 08:47 AM
ridgerunner99
Guest
 
Posts: n/a
Re: tracker broken clutch pedal!

where are you located?
post #5 of (permalink) Old 12-21-2004, 10:45 AM
Addict
 
Join Date: Apr 2002
Location: Carrollton, Georgia
Posts: 576
Thanks: 0
Thanked 0 Times in 0 Posts
 
Re: tracker broken clutch pedal!

Carrollton Georgia
ka4yqi is offline  
post #6 of (permalink) Old 11-13-2008, 01:52 PM
WB8CAC
Guest
 
Posts: n/a
96 Tracker Clutch Pedal Weld Failure

I just has the dreaded "Tracker clutch pedal weld failure." Took it out and had it welded... all is well. It's not really that much of a mightmare. If anyone is thinking of doing it, and isn't sure about it, drop me an e-mail. Have a bunch of hints. Actually wrote of a step by step procedure which includes buying beer in advance.
post #7 of (permalink) Old 04-21-2013, 10:45 PM
Newbie
 
Join Date: Apr 2013
Location: WASHINGTON
Posts: 3
Thanks: 1
Thanked 0 Times in 0 Posts
 
I too have a 96 tracker 5 spd with an identical story to ridgerunner99.
I'm getting ready to pull out the pedals now.
I'd sure like to here the suggestions from the WB8CAC guy.
Anybody got any advice?
GRASSHOPPER is offline  
post #8 of (permalink) Old 04-21-2013, 10:51 PM
Newbie
 
Join Date: Apr 2013
Location: WASHINGTON
Posts: 3
Thanks: 1
Thanked 0 Times in 0 Posts
 
I must be a new guy -so what's with all these aches & pains?
It's from trying to get the pedal cluster out or being an old geezer or both.
I have solved the mystery of how a clutch gets thicker.
The shaft that the pedal swings on broke its weld and added slack.
After running out of adjustment and even choosing a new spline at the
bell housing end, it finally broke completely. let the fun begin!
GRASSHOPPER is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Off-Road Forums & Discussion Groups forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome