First Jerry-Rig Fix on the Focus

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SwampSurvivor

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Was driving last week and pushed the clutch to stop. Heard a snap and the clutch pedal felt funny along with not coming all the way back up. I was quite close to ordering a new clutch, slave cylinder, pressure plate, etc. Figured since it had to be broken apart to replace the internal slave, I should replace everything.

It was suggested that I check the clutch return spring on the pedal. Sure enough - it was broken.

Called the dealer to try to get a replacement spring and was told I would need to buy a $200 clutch pedal assembly to get the spring. Yeah ... no thanks. Did some research, found the Ford part number and called the dealer again.

This time it was $50 ... for a spring.

Headed on down to the AutoZone and found a set of carburetor / throttle return springs. Assorted sizes. One of them was an exact match! It had no ends and was about 5' too long. Which is fine - I cut it down to size and made the ends.

Unfortunately, I had a hard time finding the location for it. Almost popped my shoulder out reaching for it. When I finally found the location, I decided against using it. From the factory, it's anchored to the pedal (good) and a piece of plastic on the pedal assembly (no thanks).

Took two of the remaining springs and anchored them farther down on the clutch pedal and then found a stationary spot on the steering column support. Works great again! Feels normal!

It isn't wrapped around the steering shaft - the picture makes it look like that. Maybe I'll get around to hooking it up as it was originally. But I can buy a lot of $5 carburetor spring packs for the price of a dealer spring!


WF88jx7.jpg
 
Originally Posted By: eljefino
Does it go "twang" in use?


Until I applied some electrical tape to the clutch pedal end, it would make the twanging noise. I think the springs were sliding around a bit.
 
Call me old fashioned but I'd rather have a factory approved spring in something as important as that, especially on a three year old car. $50 is only $50. The car is probably not even paid for yet?

Seems like you could get this spring at a junk yard for less than $5, no?
 
Originally Posted By: bubbatime
Call me old fashioned but I'd rather have a factory approved spring in something as important as that, especially on a three year old car. $50 is only $50. The car is probably not even paid for yet?

Seems like you could get this spring at a junk yard for less than $5, no?


Paid for as of yesterday, actually. Well ... waiting a few days for the e-payment to clear. There'll be a celebratory post when the e-payment clears.

I would have gone with the factory location but I really didn't like the idea of anchoring a small, high tension spring to plastic - especially since the fluid is running through the anchor point. Granted, I have never heard of the spring wearing through the plastic.

I also think this will be a bit easier on the pedal assembly. Before, it was pulling down on the opposite side of the fulcrum / pivot point - and quite hard as it was only an inch away. These two springs pull back up where I push down, and not nearly as hard since they are so far out.
 
It would probably be more hassle than it's worth, but wouldn't this be covered by Ford's power-train warranty? Bumper/bumper is done obviously.
 
Originally Posted By: JTK
It would probably be more hassle than it's worth, but wouldn't this be covered by Ford's power-train warranty? Bumper/bumper is done obviously.


Anything clutch related, apart from clutch disc itself - no warranty there, was its own warranty for 10K or 15K miles.
 
My mom used a rubber band for the carb/throttle return spring on her VW beetle back in the day. I guess she eventually had it fixed right, rubber wouldn't last long back there.
 
Originally Posted By: Miller88
Originally Posted By: JTK
It would probably be more hassle than it's worth, but wouldn't this be covered by Ford's power-train warranty? Bumper/bumper is done obviously.


Anything clutch related, apart from clutch disc itself - no warranty there, was its own warranty for 10K or 15K miles.


Interesting. Typically the clutch friction material itself isn't covered (much, if any), but T/O bearings, slave cyl, master cyl, etc... are.

Years ago I had issues with the clutch pedal on my 1994 Jeep Cherokee 4.0L 5spd. The clutch pedal would swing forward freely, but still worked. Couldn't figure out the problem. Took it to the dealer, given I *think* I was still under 3/36K warranty. They found a missing circlip had popped off and fell under the carpet. Fixed no charge.
 
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4 years old and having problems? Time to trade. Its best years are over.

*

Originally Posted By: Donald
Jury rig repairs are fine as long as they do not involve duct tape, wood or wire nuts.


You kidding? Those are the best kinds.

If I had disposable money I always thought it'd be fun to do my own Top Gear challenge with my brothers. Fly to some state, buy some jalopies, see what happens as we drive home. Points awarded per breakdown; bonus points for most creative repairs.

*

Originally Posted By: Miller88
Paid for as of yesterday, actually. Well ... waiting a few days for the e-payment to clear. There'll be a celebratory post when the e-payment clears.


Nice! I'll congratulate you in that thread too, but, way to go!
 
Originally Posted By: supton
4 years old and having problems? Time to trade. Its best years are over.


I could trade it on a new Mirage and pay cash with no payment
laugh.gif


... but I won't. I threw new tires and a hitch at it last summer. Now it needs new front brakes. It will be a while before I feel I've got my money for those.

The first 20K miles were pretty much pure city. The clutch has been pressed 1000000000 times.
 
Originally Posted By: bubbatime
Call me old fashioned but I'd rather have a factory approved spring in something as important as that, especially on a three year old car.


Since the factory one lasted so long?
grin.gif
 
I don't see anything wrong with this fix and also don't think the car should be dumped because of this minor and fairly easily fixable problem.
I highly doubt the same would've been suggested if the car in OP was a Honda or Toyota. It would probably be brushed off as a "maintenance item", followed by a remark that the car will still be good for at least 300k trouble free miles plus some other "maintenance items" like engine and transmission rebuilds
grin.gif
.

But a $5 spring breaks on a Ford and it's a sign that the car is falling apart
crackmeup2.gif
.
 
I was pulling his leg on trading it. I'm one to talk, no one brags about VW and reliability.
 
The broken spring for the clutch pedal on this Focus reminds me of my mom's 03' Focus. The gas pedal fell off.
 
I'll have to try the electrical tape on the ends of the spring. The clutch on my car has its usual cold-weather twang. There's an updated part that fixes the twang, but it's $$$ and involves ripping out the dash. All 3 pedals are bolted to the same assembly and it includes a DBW sensor for the gas pedal.
 
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