Hello,

I have a quite strange problem with my LHD 2001 Gen.2 Ducato motorhome. The plastic clutch pedal keeps breaking about once a year. It is easy enough to replace, but still leaves you in a tricky spot when it happens.
The clutch seems to be working normally, not slipping or excessively heavy to engage and the pedal returns normally.
The pedal breaks around the hasp on the back side that attaches the pedal to the clutch cable.

Anyone had any similar problems or perhaps have a solution to it?

Thank you!

Hi Peter81

It's possible that a pedal many years old could fail due to fatigue cracks. This can be worsened if the plastic is in contact with mineral based grease or oil. But it wouldn't explain failure after only a year (unless your replacements are from very old stock).

I wonder if the force on the cable is higher than it was designed for, it may seem OK but it's easy to get used to a slightly heavy action. I suggest you check the cable lubrication, and make sure there aren't any sharp bends or kinks in the cable run. Often these cables are plastic lined for low friction, but the lining can wear away over time at a bend or where the cable exits the inner at one end, especially if there is a misalignment.

Could you devise some sort of local metal reinforcement for the pedal ?

I suspect that pedals are deliberately made only just strong enough, so that they give way if you have an accident.

Could there be some misalignment between pedal and cable maybe
putting a side load on the pedal.

Hello,

Thanks for your advice guys!

I replaced the pedal today and the cable was not running as smoothly as I expected. Since it is fairly cheap and apparently quite easy to replace, I will definitely replace that next.