505 clutch adjustment
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Thread: 505 clutch adjustment

  1. #1
    Member colj00's Avatar
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    Default 505 clutch adjustment

    hi all, does anyone know of a way to adjust the engagement of the clutch on the 505's. iv had a bunch of Japanese cars before and all you do is go under the pedal box and unwind the part that clasps the pedal but these pugs dont have a threaded master cylinder rod. my 505's clutch is engaging what feels like a few millimeters from the floor, and i prefer having it engage 1/3 to half way up the travel. i've bled the clutch very thoroughly.

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  2. #2
    1000+ Posts robmac's Avatar
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    XN engined 505 there is no adjustment AFAIK and I stand to be corrected.

    However, on a 404, which is similar as I recall. A brass doover off the top of a spark plug, placed in the the master cylinder , between the pedal rod and the hole in the piston, works wonders. Heavy grease will hold in place until it's assembled.

    Usually clutch issues are due to wear in the master or slave actuating rod pivots or a bent fork in the gearbox or hydraulic issues. Any of these cause lost motion in the system.

  3. #3
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    Clutch new ?
    Then
    Try lengthening your master cylinder pushrod if you are handy with a welder.
    Pushrod or hole in pedal worn ?

  4. #4
    Member colj00's Avatar
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    ok cheers
    Current fleet:

    Toyota Yaris 2007
    Ford Falcon EL wagon 1996
    Nissan NX 1993

    Previous:

    Peugeot 505 SR 1985
    Nissan pulsar 1998
    Nissan pulsar 2000
    Toyota Corolla 1990

  5. #5
    Member colj00's Avatar
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    clutch is not new, probably 60% worn by the looks of it. and i dont have a welder (yet)

    probably due to wear, thanks.
    Current fleet:

    Toyota Yaris 2007
    Ford Falcon EL wagon 1996
    Nissan NX 1993

    Previous:

    Peugeot 505 SR 1985
    Nissan pulsar 1998
    Nissan pulsar 2000
    Toyota Corolla 1990

  6. #6
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    suggest you check the pushrod where it fits into the pedal, they can wear and eventually break.

  7. #7
    1000+ Posts Beano's Avatar
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    ^ I agree. I've had to weld them up a few times. It's a 504 problem too.

    You'll have to weld the pushrod coming off the pedal, then grind it off carefully so it's the original diameter. And weld up the hole in the pedal section too, then drill a new hole in it. This will be harder to do than you think because weld is harder metal than the original. But it'll not be TOO hard. Just punch a tiny hole in it at exactly the point where you want the hole, so that the drill doesn't drift to one side when you drill the hole.

    Scratch a couple of straight lines on the pedal before you weld it. Where they intersect will be where you drill the new hole. Gotta do it in exactly the same place as the old one...

    After you have done this, using the clutch pedal will feel SO pleasurable.
    Last edited by Beano; 1st February 2016 at 02:41 PM.
    pugnut1 and Dano like this.

  8. #8
    Fellow Frogger! TassieExec's Avatar
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    I have not had a lot of experience with these but it seems that Peugeot make the clutch rod sacrificial, in other word it wears first, so I simply bought a new rod for my son's car and all fixed, a worn clutch rod can make a surprising difference.
    Regards
    Neil

  9. #9
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    A piece of similar size steel rod or if you do not have simply a bolt of the correct length -chew the end off to suit and away you can go again-spitting bits of steel-Yes or No!!

  10. #10
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    just thought of a better idea-maybe chew up the bits of the bolt-add a few extra minerals -add some fulvis acid & that should take care of any iron deficiency you may have for quiet a while-MAKE SURE SPIT ANY LED OUT BEFORE YOU SWALLOW!
    colj00 likes this.

  11. #11
    1000+ Posts Beano's Avatar
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    Quote Originally Posted by TassieExec View Post
    I have not had a lot of experience with these but it seems that Peugeot make the clutch rod sacrificial, in other word it wears first, so I simply bought a new rod for my son's car and all fixed, a worn clutch rod can make a surprising difference.
    Regards
    Neil
    If you take out the pedal in that car (or at least have a very close look at it) you will see that the rod has chewed out a large oblong hole.
    I recall the first time I was describing fixing my clutch to my local Pug repairer (who was a mate). He interrupted and said " and the pedal was worn almost through, right ?".
    It's common, and the rod is not sacrificial........though it should be.

    I might add/repeat that it is very impoortant that after welding up the hole in the pedal, that you drill the new hole in the EXACT part where it once was. Just a difference of 5 mm will make a difference to the pedal throw.

  12. #12
    Fellow Frogger! Bruce Llewellyn's Avatar
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    505 clutch adjustment-img_0071.jpg Sasic kit 18 months 7,000 km. Fixed by bashing it back down & welding. No more problems.

  13. #13
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    I second the badly worn push rod and the badly worn hole in the pedal.

    I had the push rod fail worn thru in Wagga late one night.

    Tim

  14. #14
    Demannu-facturing! Demannu's Avatar
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    The last time that I had a pedal wear a hole elongated, I welded it up, ground it flat and redrilled it, then heated it to glowing red and quenched it in old sump oil. Then it won't wear!

    I've often thought about drilling the hole out to about 15-20mm and pressing a small bearing in there - wouldn't be hard to do and would increase the area that the load is spread over. May even improve the pedal feel, but that's never really been a problem IMHO.
    Scotty

    Melbourne - Dandenong Ranges

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