Greetings again, friends! My clutch cable snapped while driving and I had to drive it 75 miles without a clutch. This was a new cable installed about 3500 miles ago at a repair shop when my Transit broke down the first time, on its maiden voyage after purchasing it, about 1 1/2 years ago. The problem then apparently was that the cable had slipped off the yoke at the transmission and possibly also snapped at the pedal. I can't remember everything. I know for sure that the clutch yoke/fork was worn out and bent, and I replaced it later with a good one a few months later when I replaced the clutch. Anyway, that is not the problem this time. When the shop made this repair 1 1/2 years ago, they jerry-rigged some kind of system using the 1995 parts but with a new cable for a manually adjusted clutch pedal system (because that was the only cable available during that emergency). My Transit, being a 1995, apparently has the older self-adjusting mechanism. Anyway, the repair seemed to work find until last week, and it snapped at the clutch pedal attachment just now.
I ordered new parts from the Transit Center, including the black plastic carrier which holds the end of the clutch cable as it bends around and attaches to the pedal. This black plastic carrier is designed for the manually adjusted system. I also ordered a new manually-adjusted cable, as I would like to switch over fully to that newer style. My Transit still has this black plastic carrier from the older self-adjusting system in it at the moment, but it seems to have been altered significantly to attach the new manually-adjusted cable, with holes drilled through it and bolted together to alter the pivot point of the carrier itself. Frankly, I don't know if any parts are missing, or needed to switch over to the newer manually-adjusted cable system. The new black plastic carrier to which attaches the cable doesn't seem to match up at all with my pedal! Do I need a new pedal as well, in order to make this work?!
So I'd greatly appreciate some guidance as to what parts I'm supposed to have: every single part, including springs, bolts, bushings, etc. And how to put everything together properly. The info in the Haynes manual is not very helpful. If I am going to need a new pedal to make this system work, that will present further challenges to me, since I only have the original pedal for the self-adjusting system. Also, please inform me as to the exact routing of the cable itself from the firewall to the transmission. There are plenty of parts and hoses down there, including the exhaust manifold, and I need to know the routing prior to doing anything with the pedal and cable attachment.
Thank you for your help!