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Ok, so here is the issue:

On release of the clutch pedal, when the car is on or off, in gear or out of gear the clutch pedal unit makes a sound. Right at the top of the throw, just before I remove my foot, there is a "clink" sound. When the sound started, I thought it was more of a creaking sound, like the bearing that the pedal pivots on needed oiling, but when I put my head in the foot well to look and listen, it really sounds more like a "clink"

I was reaching around in the foot well trying to figure out where the sound was coming from but I was completely unsuccessful so far. has anybody had this sound before?

I'm not sure if everyone's clutch feels the same as mine, but mine almost has two distinct parts of the pedal throw. The first half is very soft, leaning your foot on the pedal will depress it halfway. The second half is much harder, and it feels like this is the only portion that actually does anything.

I've looked on the forum for anything on this topic, but couldn't see anything.

Thanks guys and girls

-Phil

Couple of thoughts;

1) Clutch hose is about to let go and it is ballooning giving you variable pressure

2) Clutch inspection port plug is missing and clutch fork needs lubrication.

Jay

unfortunately if the fork bearing needs lube, it's probably toast and will require replacing

It really sounds like the sound is coming from the actual pedal assembly, underneath the dash. has anyone had this sound before?


As for the funny feel to the clutch, I am planning on replacing the clutch hose with the SS one from RS barn, so hopefully that fixes the funny pedal throw I'm seeing...

could just be the spring

haha!! oh damn! of course this happens to me, i seem to attract the most ridiculous situations.

I went out to the car to try to figure out what was going on. It turns out the noise and the clutch pedal feel are both symptoms of the same problem. The firewall is separating from the unibody!!

I had my girlfriend press the clutch after several minutes of me upside down in the footwell didn't get me anywhere. I opened the hood and started to listen if the sound was coming from the clutch master cylinder. It's not, but the whole thing cocks sideways a bit when you press the clutch, you can actually see the vertical firewall panel that the clutch and brake master cylinder are both mounted to pull away from the rest of the body. Starting from the left side of the car, peeling towards the center of the car, cocking the master cylinder a few degrees, and even moving the brake booster. Holy crap. It probably seperates 0.5" to 0.75" from the seam where it should be connected when the clutch is fully actuated. That seems completely pathetic to me, has anyone else had this happen? what do i do, have someone weld the seam? shove a bit of wood in there to jam it in place?

you install a firewall brace - i just sent you a PM with my phone number

Thanks Flash, this site is like having an "easy button"

<!--quoteo(post=78966:date=Aug 27 2009, 10:01 PM:name=flash)-->QUOTE (flash @ Aug 27 2009, 10:01 PM) <{POST_SNAPBACK}><!--quotec-->you install a firewall brace - i just sent you a PM with my phone number<!--QuoteEnd--><!--QuoteEEnd-->
Flash - this is the first I've heard of the firewall brace. How difficult is it to install? Can you send me any more info? I seemed to have misplaced your cell phone # (I purchased one of the original cab braces)

Thanks,
Phil

you can see it on the rs barn site

there is also a thread here about it - do a search, using "more options" and filter by my name and thread title

<!--quoteo(post=80489:date=Sep 22 2009, 05:44 PM:name=flash)-->QUOTE (flash @ Sep 22 2009, 05:44 PM) <{POST_SNAPBACK}><!--quotec-->you can see it on the rs barn site

there is also a thread here about it - do a search, using "more options" and filter by my name and thread title<!--QuoteEnd--><!--QuoteEEnd-->
Cool - Thanks for the info.