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V8 - '84 242 Auto to Manual Pedals... Uh Oh! Problems!

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'84 242 Auto to Manual Pedals... Uh Oh! Problems!

While waiting for front susp. parts, thought it would be a good time to swap out the auto trans pedal to the manual clutch/brake assy. on my '84 242DL Ford V8 T-5 project. And then-problems. The clutch/brake pedal assy from my '83 242 Turbo parts car has a simple single arm with about a 5mm clevis pin mounting for the clutch cable. I have a 2nd clutch/brake pedal assy. of unknown origin that came with a parts lot. It appears nearly identical, but has a very different and more elaborate, heavier duty mounting for the clutch cable- 3 welded on vertical arms and a plate with a slot and a formed groove. A new clutch cable, (also of unknown origin), came with this assembly that has a "T" end on it that seems to fit perfectly, so seems likely the pedal was intended for a cable clutch, not a hydraulic. The '83 turbo parts car is long gone and the clutch cable went with the motor when sold, so no way to compare.
Though I thought I stripped off every conceivable thing of possible use from the rusty hulk before it went to the crusher, it seems I missed taking the plate on the firewall that mounts the brake booster and the clutch/brake pedal assembly and the plates are different auto trans vs manual.
Looks like the manual trans pedals don't really attach directly to the plate, so maybe only drill the hole for the cable grommet?
And to this, on the clutch pedal side of both assys. on the side facing the firewall, there is a hole about an inch and a half in dia. Above and below this large hole are 2 smaller hole with weld nuts on the firewall side. The pedal assy from the '83 Turbo has a vacuum hose running through the large hole that feeds through a gasketted plate that lines up with the 2 smaller holes. The "unknown" assy shows no sign these 2 holes were ever used. I remember that the Turbo car was so pathetically under powered that the A/C would cut off when accelerating. Is that was this was for?
I've tried to find answers for these questions here and on other sites, but no luck.
Can anyone shed any light on any of this?





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    '84 242 Auto to Manual Pedals... Uh Oh! Problems!

    Your vacuum line "hole" -- on my 82, that was blocked off. My understanding is that's where a hydraulic clutch car would've had it's clutch cylinder/reservoir - so the clutch linkage 'pusher' would've passed through there. I've got some wiring loom for gauges and such passing through there on my conversion. As for bolting up/mounting of manual vs auto pedal assemblies - mine's always been manual; so I'm no help to you.





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      '84 242 Auto to Manual Pedals... Uh Oh! Problems!

      Michael,You have been a GREAT help to me and many others here and I sincerely THANK YOU! It is invaluable to ask someone who has actually been there.
      I have looked intently at every photo I could find on the clutch pedal assembly- EBay items for sale, the "Bentley Bible", Haynes manual, etc. All showed the pedal with the clevis pin attacment. None showed this other assembly I have with the different cable attachment. It has the same mounting points, is visually identical to the one I took from my "83 242 Turbo parts car, save for this. The Parts lot it came in came with Ford motor mounts, a large, rather decently made, bolt-in mount, a new, unidentified clutch cable, a bunch of small items including a rather odd, sort of "slide in" trans mount and an unused 25mm IPD dropped front sway bar. The guy said it came out of a 242 Bertone coupe, the one with the big, chopped roof, that was decaying away along with a couple of other 244s behind a derelict house.
      This other assembly looks entirely OEM, not modified. The cable it came with has a "T" style end and this fits perfectly into the mounting point on the pedal. Maybe it's from a 700 or 900 series car? I wish I had kept the "83 Turbo cable and the firewall plate, but long gone.
      On that vacuum hose and the diamond shaped plate= The "83 Turbo pedal assembly still has the vacuum hose passing through the grommet on the plate as it came off the car. I believe it went to a switch to kill the A/C compressor on heavy acceleration; will pore over wiring diagrams for answer. The hole for the cable to pass through is above this plate, right up at the top and is clearly shown in a photo in the Bentley book.
      The question is; which pedal assembly will work best with the Ford clutch cable? I have the book "Official Ford Mustang Technical Reference & Performance Handbook" by Al Kirschenbaum, and it details a rather confusing series of updates and variations on cable clutch mechanisms; self adjusting, manual adjusted, non-adjustable, heavy-duty, Cobra variants, different release forks, bell housings, etc, etc. Makes you dizzy. But it DOES have FRPP part numbers!
      Any recommendations for which Mustang cable to use?
      This started out as an easy project to do while waiting for suspension parts. I hate taking things apart and not finishing the job as parts grow legs and get lost. Colder than hell in my unfinished garage expansion!





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        '84 242 Auto to Manual Pedals... Uh Oh! Problems!

        Not sure I can help much as mine was already set up when I got it. Appears to have the yellow plastic adjuster that fits into the hole on the bell to align the cable housing with the clutch arm and the spiral metal sleeve protecting the cable. If that pedal set you have is for a 700 series (no 900 US manuals) it won’t work on the 240.
        --
        82 242-6.2L; '17 Mazda3; '16 Crosstrek





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          '84 242 Auto to Manual Pedals... Uh Oh! Problems!

          The main "cage" or bracket is identical to the one I took off the '83 242 Turbo. It is just the top of the clutch pedal where the cable attaches that is different= definitely made for cable with "T" end. . Definitely not a hydraulic pedal- pulls, not pushes.
          Nearest Volvo dealer is about 30 miles away, parts dept. pretty useless for anything more than 5-10 years old. Maybe local Beck-Arnley store can help.
          200 Volvos VERY rare to find in junkyards here around Detroit for comparison, road salt got 'em decades ago, all gone to the crusher. Mine came from Arkansas, dents & scrapes but ZERO rust





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            '84 242 Auto to Manual Pedals... Uh Oh! Problems!

            Finished installation of pedal assembly- what a PIA! My neck is gonna hurt for weeks! And my ribs! from leaning on the door sill trim-OUCH!
            Since I have both style pedals, if one doesn't work out, easy to remove pivot bolt and swap in the other pedal.
            Same if I ever find a pedal for a hydraulic clutch, as I did punch the holes in the firewall plate while I had access and covered the holes with the "diamond" shaped plate





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        '84 242 Auto to Manual Pedals... Uh Oh! Problems!

        Seems the "search" function here has a limited scope. I went back to 2001 to see if there was any info on identifying this odd clutch pedal. A poster, "wongg" in 2002 referred to Ross Converse saying that there were two different pedals used on 200s and elsewhere some one thought that the 260 diesels used a cable clutch. I'd thought that ALL diesels used hydraulic. Maybe that's what this thing is? 260 diesel?
        Also, way back then there were postings of the "T" end of the cable breaking off. The new, unused cable I have has this "T" on the upper end and the plastic Volvo adjuster and a ball on the lower end. It appears to be a pretty stout item. Better to use this cable with the "T" and the corresponding pedal? Or the '83 242 Turbo item with the clevis/pin?
        Next step, I guess, is to compare this style cable to clevis end cable to see which is stouter and available when replacement needed.
        On that "diamond" shaped plate with the vacuum line running through it; This other pedal, (for now assuming it may be a 260 diesel item), shows no sign of bolts ever being in the weld nuts, no marks from mounting the plate, looks never used.
        Drilling the hole in the firewall plate for the grommet and cable as shown on page 410-2 in the Bentley book looks fiddly, but do-able.
        Photo, "Fig 3" on same page shows clevis/pin attachment with the caption, "Early cars use clevis pin and cotter pin (arrow) as shown. Later cars use bolt and locking clip". But I can't find a photo of this.





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