Genius G540 EPROM Programmer - Installing on Windows 10
Replacing Clutch Pedal Return Spring on Ford Focus
If you install the software for the Genius G540 EPROM Programmer on Windows 10, the main software package (G540EngSetup.exe) should install correctly but you will probably get an error when you try to install the USB driver package (StglCproUSB_Installer.exe). The problem is that the USB drivers are not signed. To get round this, you need to temporarily disable Windows 10 driver signature enforcement, then install the USB drivers. To do this (make a note of or print the following instructions as you won't be able to read them after step 4):
You may find that Windows periodically disables the driver, so you might occasionally have to uninstall it and repeat the procedure above to re-install it again.
Note: the Programmer draws around 230mA from the USB port when programming and can exhibit strange or inconsistent behaviour if connected to a USB port that cannot provide enough power.
Replacing a broken clutch pedal return spring on a Ford Focus is a bit of a pig of a job. I done a bit of reading on various websites here and here about how it could be made 'easier' by stretching the spring with coins before trying to fit it. I ended up using a variation of this method, as described below, which would enable me to replace another one quite quickly.
What you'll need:
The coins and flat bar are used to stretch the spring. To fit these:
Park the car where you can open the driver's door fully. Inside the car, slide the driver's seat as far back as it will go, and adjust the steering wheel so it is as far back (towards the seat) and up as far as it will go.
You'll need one torch in the footwell, pointing up towards the clutch pedal pivot. With the head torch, push or tape it so it is pointing through the gap just above the trim panel beneath the steering column. Looking through here, you should be able to see the 'notch' at the top of the clutch pedal where the long end of the spring will locate.
Thread the string in through the gap where the head torch is pointing, over the top of the clutch pedal pivot and into the footwell (use the coat hanger wire to help thread it through). Tie the string to the loop on the long end of the spring.
Hold the short end of the spring, near the coils, with the long nose pliers, with the open side of the hook facing away from you. Working in the footwell and looking up, hook the short end of the spring through the hole in the clutch backing plate. It's not particularly easy to see (look at the photos on the two websites linked to above) and may take a bit of fiddling. Hold the spring in the pliers as vertically as possible. Once fitted, put some tension on the string to stop the spring from falling down.
Working through the gap where the head torch is pointing, use a loop on the end of the coat hanger wire to guide the long end of the spring onto the notch at the top of the clutch pedal. It should go quite easily; it shouldn't be necessary to stretch the spring any more.
Using one hand, push down the clutch pedal, and tease the two coins out of the spring using the pliers or coat hanger wire. The bar will remain inside the spring but this won't cause any problems.
Using the coat hanger wire, tease the string off the end of the spring hook.