I have written about this before. There is a small white nylon/plastic
part ( I'll refer to it as a connector, Haynes calls it a clip) about
the size of two fingers put together that connects the clutch pedal to
the clutch cable. The nylon will dry out over time and the connector will
break. Ever since this happened to me, I have kept a spare connector
(cost: $5-7) on board in case it happens again. I gave another one to my
brother-in-law who also has an '89 Mi16. The clutch cable in these cars
is well built, and unlikely to break.
I cannot recommend loudly enough to all 405 owners ( with manual trans)
the need to have a replacement connector on board. This break down will
strand you on the highway, and if you have the part on board, any
mechanic can make the repair, or you can do it yourself. Can Lew or
someone post the part number?
A few comments:
I have the connector, and would send it to you if you can't find one
yourself. My dealer did not have one in stock, But Lew Baille or someone
could send you one, perhaps even overnight if you need it. If you order
it, ask for both the connector and small metal retaining clip. They just
sent me the connector, so I had to re-use the clip (which is flimsy and
could bend out of shape)
Do not pull the clutch cable through the firewall from the engine
compartment. You do not need to extract the cable to replace the broken
connector, and it is a hassle to put it back through the firewall.
You might wait until you get the new connector before you remove the
broken one. It is a funny shape, and I remember thinking it sure would
have been easier if I remembered how the old connector looked installed.
I kept saying "does it go like this? or like this?"
The Haynes manual discusses adjusting the cable, dropping the pedals, and
other related topics.
To remove the broken connector:
1. get on your back, head by the pedals, looking up at the area above
the pedals.
2. Locate the white plastic connector that is probably broken and
swinging freely.
3. With needle nose or other small plier and maybe a small screwdriver,
pry the black retaing clip off the middle of the plastic connector...pull
the clip straight down toward your face.
4. You can now remove the broken connector from the clutch cable, which
has grooved bullet-shaped end (the grove and retaining clip connect the
cable to the plastic connector)
5. Re-attaching the connector is the reverse ,and should be obviou,
noting that you may have to put some slack in the clutch cable and then
tighten it back up. The aduster nut is located underneath the battery
tray in the engine compartment......I had to remove the battery and tray
to do it properly.
6. the part of the connector that broke was most likely the end that
attaches to the clutch pedal......it is the weakest. It is awkward and
difficult to re-attach the connector to the pedal because of limited
space and the sharp angle of the pedal. Mine was replaced by dropping the
pedals.......I did not do this, but i was told it was pretty easy. just a
couple of bolts and voila.
7. The plastic connector has a small arm that activates a switch related
to the cruise control I think. make sure that it is properly attached.
I will be reading my email over the weekend, if you need more info please
email me back.
Mike Savage