LUVTruck.com

Does anyone know if the firewall is weldable on the LUVs? There's a bracket on the inside of the firewall that the clutch cable passes through. Mine broke yesterday, and the pickup is undriveable (No clutch) until I fix it.

I'm concerned because the bracket doesn't show any signs of rust, even where the metal was fatigued, which tells me it's an alloy of some sort. (Personally, I didn't know these pickups had any sheet metal that didn't rust.)

Has anyone figured out a good way to fix this?

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'82 Luv 4x4 diesel
270k miles
35MPG

1972 XLCH
1974 FJ40
1967 Chevelle
2004 Sienna (OK. That's the wife's)

I have repaired two Pups. It is not too hard to do. YMMV.

1. the clutch cable needs replacing. Remove it and order a new one. The firewall is paper thin around the hole where the clutch cable goes through. The cable was worn out internally and the drag increased ALOT and stressed out the paper thin firewall around the bracket.

2. fit the broken part back into place with a small tack weld using a wire feed welder with the lowest setting you have. weld steel washers around the stressed area to spread out the stress. you can put a wet towell inside the firewall area under the dash, this will suppress the tendency for the sheet metal to melt and burn through when welding.
Only weld a tiny portion at any time, letting things cool down before continuing, taking care not to burn through the thin firewall.

I build up the whole area around the hole the clutch cable goes through with a couple of hours of patient welding spaced with cool off periods using the smallest wire my wire feed welder can use. "030" IIRC.

When done, the area is probably 3x thicker a good inch all the way around the original hole. I did not bother to weld from the inside.

Scott--

I fixed mine by fabricating a plate that sits on the engine side of the firewall and spreads the load as broadly as possible. The plate is held in place by machine screws from the inside. Also, I removed the ferrule that the cable nests in and brazed it into the new plate. This works well (so far) and requires no welding on the firewall.

This subject has been discussed a number of times on the IsuzuPup forum so you might take a look over there.

Paul

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'84 Isuzu diesel P'up

Scott,

There are a few threads on this subject, but one of them even has a scan of the Isuzu Technical Service Bulletin describing this problem (courtesy of Finalman, who is a member at IsuzuPup.com as well as this forum). The TSB even lists an Isuzu part that was made to address this problem. I don't know if the part is still available, but some have just welded a large washer to the firewall.

Here's the thread with the TSBs.

Jack

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'83 Isuzu P'up Diesel LS - Original Owner
JoeIsuzu@IsuzuPup.com
IsuzuPup.com

Thanks for the replies everyone. Weather and work finally cleared up enough for me to tow the pickup home and weld the old cowl plate (who thinks of these names?) back on. So far so good.

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'82 Luv 4x4 diesel
270k miles
35MPG

1972 XLCH
1974 FJ40
1967 Chevelle
2004 Sienna (OK. That's the wife's)

cowl (koul), n.
1. a hooded garment worn by monks.
2. the hood of this garment.
3. part of a garment that is draped to resemble a cowl or hood.
4. the forward part of the body of a motor vehicle supporting the rear of the hood and the windshield and housing the pedals and instrument panel.
5. a cowling.
6. a hoodlike covering for increasing the draft of a chimney or ventilator.
7. a wire netting fastened to the top of the smokestack of a locomotive to prevent large sparks from being discharged; a spark arrester.
–v.t.
8. to cover with or as if with a cowl.
9. to put a monk's cowl on.
10. to make a monk of.
[bef. 1000; ME cou(e)le, OE cugele, c%le < LL cuculla monk's hood, var. of L cucullus hood]

I painted my cowl black on a yellow '78 LUV. I would never weld it on.

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'78 1.8L 4-speed Fleetside

The only thing more beautiful than a sunset is a sunrise.