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welding a broken clutch pedal back together
09-26-2015, 11:18 AM
Post: #1
welding a broken clutch pedal back together
Hi, I’m new here and new to Sidekicks/Trackers.
I have read almost every FixKick webpage (so much great info; thank you FixKick!) and much of these forums but still cannot find some answers.
If I’m a blind idiot please point me in the right direction.

I’ve picked up a 1997 Tracker cheap because the clutch pedal has broken …again.
1997 Geo Tacker base 4 door, 5-speed, 4WD [VIN 2CNBJ12666V690…]
Square end clutch pedal rod.

1.
I cannot find anyone selling the pedal (arm & rod) or the pedals assembly.
Is anyone still selling parts?

1b.
So many part numbers on FixKick (Thank you!) but I’m not sure which one/ones are correct— 49810-62AF1, 49810-58B21, 91173175, 91172672.


2.
My clutch pedal arm has been welded once or twice before. I expect to weld it again but I don’t know the correct position/angle.
Does anyone have the Arm angle position (relative to a fixed part, eg: the upper stop)?

(Yes. I have a fresh clutch cable ready to install.)

Thanks Stephen
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09-26-2015, 07:47 PM (This post was last modified: 09-26-2015 07:50 PM by fixkick.)
Post: #2
RE: welding a broken clutch pedal back together
as you know....
the pedal breaks for 2 reasons, the cable is bad, (I goes bad inside where no man can see)
the cable inside gets a deep groove, and pinches the internal cable, badly....
or the stock crappy 2 point spot weld fails on pedal. (these two facts help (sick) each other)
Suzuki still sells the pedal. (not sure on GM, which is same but diffr. P/n and is missing im my Geo book.)

last time i checked, 1year ago? they had them.

since you you show fulls spec on car this is easy to p/n exact. 5sp, 4door, (ill answer for non cruise option)
there are 2 numbers, one japan and one CAMI
the CAMI is best number IMO

49810 prefix both
dash 62a52 japan
dash 62AF1 Cami

49810-62AF1 (bingo)
shows here.
http://www.suzukicarparts.com/parts/1995...eid=214820

thanks your welcome, as always...

http://www.fixkick.com
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09-28-2015, 06:58 AM
Post: #3
RE: welding a broken clutch pedal back together
After replacing my clutch cable the clutch is still in heavy drag.
So on to that pesky clutch pedal. With FixKick’s guidance I contacted Suzuki Depot. Denise was incredibly patient during locating my clutch pedal details. She even pulled the part and sent me a photo of the shaft end to confirm it matched my Tracker’s.
After I placed my order she followed up with the full pedal assembly (clutch, brake, gas) exploded view by email.

Wow, I don’t ever recall getting such excellent service from a parts retailer.

Denise, Suzuki Depot/Tom's Truck Center
12221 Monarch St
Garden Grove, Ca. 92841
(800)238-9308




Stephen

1997 Geo Tracker four door, five speed, all wheel drive, cruise control, and just a little bit of rust …everywhere

   
   
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09-28-2015, 09:02 AM (This post was last modified: 09-28-2015 09:06 AM by fixkick.)
Post: #4
RE: welding a broken clutch pedal back together
thanks! for that shaft end, photo. some have splines..
thanks to one contrib.named mike.
we have these nice shots. too


http://www.fixkick.com/tranny/clutch/mik...index.html

other pedal drag causes.?

1: collapsed throw out bearing
2: or bearing just jamming on its guide (front of trans)
3: or the clutch disk spline jamming. (it bad or the splined pilot shaft galled)
4: damage to the forked, throw out actuator rod, assembly, or bushing failure there, or one fork busted off or bent.

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10-04-2015, 09:06 AM (This post was last modified: 10-04-2015 09:12 AM by woolverton.)
Post: #5
RE: welding a broken clutch pedal back together
(09-26-2015 11:18 AM)woolverton Wrote:  Does anyone have the Arm angle position (relative to a fixed part, eg: the upper stop)?

I have my new 49810-62A52 clutch pedal.
So others can repair their pedals here’s the relationship between arm and shaft square end:

   
   
   
[ ignore the “UP” markings on the box :-) ]



Stephen
1997 Geo Tracker 4-door, 4X4, 5-speed
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10-04-2015, 09:10 AM
Post: #6
RE: welding a broken clutch pedal back together
superrrrrrrrrrrrrrrrrr!

thanks

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10-04-2015, 09:17 AM
Post: #7
RE: welding a broken clutch pedal back together
I’m pulling out my old pedal. [The PO welded it back but at ~25° off!]

The pedal swings smoothly in the assembly. The shaft slides in its sleeve.
BUT…
the shaft will not come out any further than the last little bit!

Am I missing something? Is there a trick to this?


   
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10-05-2015, 11:53 AM
Post: #8
RE: welding a broken clutch pedal back together
(10-04-2015 09:17 AM)woolverton Wrote:  I’m pulling out my old pedal. [The PO welded it back but at ~25° off!]

The pedal swings smoothly in the assembly. The shaft slides in its sleeve.
BUT…
the shaft will not come out any further than the last little bit!

Am I missing something? Is there a trick to this?

Is the continued slide outward being blocked by something on the opposite side of the shaft preventing it from going further? Hitting that black panel stuff? Only other thing you'd think would be if shaft there at the splines/bolt area is out of round, bent, or has a burr or something keeping it from entering that final portion so it can exit?

Wish I could help more. Nice pics you've posted.
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10-05-2015, 01:53 PM
Post: #9
RE: welding a broken clutch pedal back together
(10-04-2015 09:17 AM)woolverton Wrote:  I’m pulling out my old pedal.
Am I missing something? Is there a trick to this?

answer: get a bigger hammer
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10-06-2015, 01:27 AM (This post was last modified: 10-06-2015 01:28 AM by GeoHacker.)
Post: #10
RE: welding a broken clutch pedal back together
(10-05-2015 01:53 PM)woolverton Wrote:  
(10-04-2015 09:17 AM)woolverton Wrote:  I’m pulling out my old pedal.
Am I missing something? Is there a trick to this?

answer: get a bigger hammer

Ha. Smile Glad you got it worked out.

In my situation, smacking on my final bearing, the 1/2 pound dead blow worked better than the 2-3 pound rubber mallet. Though earlier, the rubber mallet set the countershaft just right.

Great looking pedal. NAPA carries nice rubber pads for Tracker brake and clutch pedals, $3 I think. Now my foot won't slip off the clutch after rain anymore. I am going to buy a spare set in case they go away.
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