Hey all, having a bit of an issue with my 1984 2m4. I recently took out the old clutch master cylinder, which the rod had broken off in the middle, but in putting a new one on, I have discovered that they don't fit, well the end does go onto the pedal connection, but it is at an angle, and the end does not go on deep enough to put on the clip, so it slips off. Pics included. What can I do to make it fit?

Looks like the hole in the banjo was improperly punched during manufacture, leaving a burr as a defect:



I suggest removing the MC from the car, then use a drill to remove the burr. Secure the banjo in a vise.

With the burr removed the banjo should slip onto the pin. Be sure to test the fit between the banjo and the pin, before bolting the assembly into the car.

As a matter of good practice, remove any sharp edges you may have created following drilling.

********************************************************************************

I'm also wondering if there was some parts mismatch error that caused your first banjo to break...

[This message has been edited by pmbrunelle (edited 09-29-2020).]

There are different sized banjos. '84 normally takes one with a larger hole. Check out This page. And seriously, this is where everyone should be buying their Fiero clutch master and slave cylinders from. Absolute top notch.

[This message has been edited by Patrick (edited 09-29-2020).]

quote Originally posted by Patrick: There are different sized banjos. '84 normally takes one with a larger hole. Check out This page. And seriously, this is where everyone should be buying their Fiero clutch master and slave cylinders from. Absolute top notch.

Thanks, this helps a lot! Do you think I could drill it out larger, or should I just cut my losses and buy a new one? This clutch master cylinder replacement came from the previous owner with the car.

quote Originally posted by 842m4SE: Do you think I could drill it out larger...?

The problem is... you don't want steel rubbing against steel. The shaft on the pedal would start wearing. I think the original master cylinders/banjos had a nylon bushing of some sort, and I believe the Rodney Dickman ones have an Oilite bushing. If you could find a bushing to use, sure, drill the hole bigger... or buy an adjustable banjo from Rodney with a bushing and the correct size hole.

Like Patrick said, Rodney is the one and only place fiero owners should buy their clutch related cylinders from, no question.

Best design, quality, and price !!!

Thanks Rodney.

------------------
fierogt28

88 GT, Loaded, 5-speed.
88 GT, 5-speed. Beechwood interior, All original.

Could it be possible that the clutch pedal bracket is bent, as is a common thing with Fiero clutch pedals? The pin looks to be at an angle and the switch plunger button appears to be off-center of the contact pad. A bent clutch pedal could be the reason the original pushrod broke.