Clutch Lever Boot

Opportunity

MWR had been manufacturing a clutch lever boot for an existing automotive customer for a number of years. When a newer model was introduced the pivot point on the clutch lever moved back from the original position.

Challenge

The customer continued to install the original clutch lever boot in the new model, but it was soon discovered that the existing boot was failing in the field, so the customer wanted to slightly redesign the boot to give it more travel. MWR’s engineering team determined that there wasn’t enough room to make a functioning boot.

Solution

MWR proposed a boot cover (instead of a flexing boot design) that would cover the clutch lever up to and including the pivot point, which effectively eliminated the failure mode. This redesign, which varied from the original proposal, also allowed for future vehicle build variations, a plus for the client.

Results

In addition to giving the customer a solution that would encompass future designs, there were zero failures once installed.