How To Make Your Own Clutch Freeplay Kit

Posted by on October 9, 2011 - one

After attempting to adjust my clutch…again, I finally started looking into the freeplay kit offered by a company in the Mustang community. Being an instant gratification and cheap person I decided the price of said product was quite high for what you were getting and I wanted it done this weekend.

So, after some research and time spent at the local Lowe’s hardware store, I came up with a much cheaper alternative that works just as well.

The Problem
When you install an aftermarket clutch setup the factory adjustment mechanism simply doesn’t do the trick any longer. The easy fix to this problem is going with an aftermarket firewall adjuster and quadrant. The problem I ran into and several other people have run into is the throw out bearing simply will not stay off the pressure plate when you have the clutch comfortably adjusted.

There are a few ways to fix this issue, the best way to fix the problem is to run a different clutch fork to change the geometry of the entire system. Being the cheap person I am I looked into other options and the freeplay kit peaked my interest.

What You Will Need
These are Lowe’s part numbers, you can probably find similar products at any home improvement store.

246632 PB Spring Comp #47 – $3.49 (the spring shown and the package for the spring)

115970 1/2-3/4″ PVC Male-Female adapter – $0.72 (the small round pieces at the bottom of this picture)

The spring only comes as a set of two, so realistically for another 72 cents you will have two complete kits.

How to assemble
Pull the clutch dust shield off the transmission and detach the clutch cable from the clutch fork.

Slide the adapter piece over the end of the clutch cable with the smaller hole towards the back of the car (this is what the spring will sit on).

You will need to modify the spring slightly to make it fit over the clutch cable. I used a pair of needle nose pliers and pried each end of the spring outward slightly a few times to get the proper clearance. Once you have enough clearance slide the spring over the end of the clutch cable and set it against the adapter piece.

Now comes the tricky part. While holding the spring away from the end slide the clutch cable back into the clutch fork and let the spring rest against the clutch fork.

Your setup should now look like this:

Now crank the vehicle and with it idling in neutral with the clutch released climb back under the vehicle and check for the throw out bearing spinning against the pressure plate. Using your firewall adjuster get the bearing to sit slightly off the pressure plate, the spring will allow you to adjust it slightly closer without the bearing sitting against the pressure plate.

Once you have it adjusted put the dust shield back over the transmission and set the car back on the ground and enjoy your newly adjusted clutch.

I know there are several pictures missing in this setup and if you want any specific pictures please let me know, probably going to go disassemble this setup and attempt to take step by step pictures now, just wanted to check for it actually working first.

For more information on this how-to head on over to our forums for discussion.

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  • Anonymous

    Excellent idea and write up!
    Could we get some more information on the spring dimensions?
    O.D., I.D., coil diameter, coil count and overall length perhaps?

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