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Discussion Starter · #1 ·
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!!!!!!
 

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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.
 

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""""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.
 
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Discussion Starter · #6 ·
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.
 

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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!
 
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