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Author Topic: 91 xr2 hydraulic clutch conversion help  (Read 345 times)

ShadetreeMechanic13

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    • 91 mercury capri xr2
91 xr2 hydraulic clutch conversion help
« on: June 26, 2018, 04:23:30 PM »

Does someone know what different way to do a hydraulic clutch conversion? Have read about the n/a having a hydraulic clutch and the xr2s having a cable. I've gone through 3 new cables and I'm told they will keep breaking.
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greywolf27030

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Re: 91 xr2 hydraulic clutch conversion help
« Reply #1 on: June 27, 2018, 06:59:03 PM »

Interesting problem Shadetree, wonder why they keep breaking?  Heavy duty clutch, bind in the cable?  Find a N/A, get the pedal assembly, master, slave and connecting tubing.  Then you'll fabricate a bracket to attach the slave to the cable operated clutch arm.  If you can't find anything on it by searching TeamCapri, check out the Festiva forum.  I've seen info of this in one or the other with pictures.

Jack Byrd
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Rocketman

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Re: 91 xr2 hydraulic clutch conversion help
« Reply #2 on: June 27, 2018, 09:42:59 PM »

Hah, the Festiva guys running the Escort hydraulic transmissions do a cable conversion to it. The festiva F-type is cable.

I've heard aftermarket cables are not as durable, but have no evidence to back that claim up. I run stock cables with a heavy duty pressure plate and have had zero issues.
My clutch is very heavy compared to the stock one.

Where are the cables failing?
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1.8L Turbo All Wheel Drive Capri... the "GTXR2"


ShadetreeMechanic13

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Re: 91 xr2 hydraulic clutch conversion help
« Reply #3 on: June 29, 2018, 06:23:08 PM »

I've bought 2 new cables from rockauto.com and the first one broke at the top of the cable where the metal piece hooks onto the petal. The second time on the bottom where the cable turns into a threaded bolt.
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ShadetreeMechanic13

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Re: 91 xr2 hydraulic clutch conversion help
« Reply #4 on: June 29, 2018, 06:44:23 PM »

What kind of piping does it use to connect the slave cylinder and the master cylinder? Do I need the entire pedal assembly and what plugs up from the pedals to the back of the master cylinder?
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Rocketman

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Re: 91 xr2 hydraulic clutch conversion help
« Reply #5 on: July 02, 2018, 12:13:44 AM »

Can you describe the clutch you're using? Is it an aftermarket clutch with a stronger pressure plate?

I would consider trying the ford/mazda dealership for an OEM part before embarking on the conversion. It would be significantly easier to go this route

I believe you'll need the entire pedal assembly. I don't recall the differences, but when I went to do my AWD conversion (the GTX uses a hydraulic clutch) I collected an n/a pedal assembly as the conversion of the cable pedal was too involved. (I may think differently on that now)
In the end I welded a fork onto the hydraulic actuator and made a bracket, converting the hydraulic trans to cable. 

The piping between the master & slave should be brake line, not sure if it is standard flare or bubble flare
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1.8L Turbo All Wheel Drive Capri... the "GTXR2"


ShadetreeMechanic13

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    • 91 mercury capri xr2
Re: 91 xr2 hydraulic clutch conversion help
« Reply #6 on: July 02, 2018, 10:41:00 AM »

It's a stock clutch and pressure plate from O'Reilly's auto parts. Rocketman you are awesome and I'm wanting to purchase a rocket chip from you in the near future. How much do they cost.
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SHOwn

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Re: 91 xr2 hydraulic clutch conversion help
« Reply #7 on: July 04, 2018, 08:20:45 PM »

Or pull a used one if you can find one. My friend across town had one in his hulk that had around 100k on it, good as new. It worked out fine on my car.
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R. Powell
'91 XR2, LM 16" Chrome Drifters, White Gauge Faces, Kuhmo 40's, Big Brake UG, 2.5" Mandrel Bent CATback, BMW318 Heated Seats, `94 console, '99 Dodge Neon Spoiler, '94 XR2 Sideskirts Bumpers and taillights, Fresh Basecoat-Clearcoat Cardinal Red (Jul2014), vj11/vj14 hybrid, manual boost CTL.

ShadetreeMechanic13

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Re: 91 xr2 hydraulic clutch conversion help
« Reply #8 on: July 07, 2018, 12:13:59 PM »

Does anyone know where to find the rod that push into the back of the master cylinder from the clutch pedal? I've been looking but keep coming up empty handed. I can order everything else.
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