simon.w
07-11-2009, 08:53 PM
Hi all,
well after reading the clutch sticking thread I have applied some of the advice from in there and added my own fixes.
Bottom line is that I did this last night, took the car out this morn and thrashed the crap out of it and NO PEDAL STICKING OR CLUTCH SLIPPING OR SMELL!!!
So I have pulled it all apart and started again taking pics as I went so I could share this with everyone. Dead easy ... less than 2 hours work.
Here we go:
Firstly gently pull out the front dash panel.
http://farm4.static.flickr.com/3520/4081979425_d45e90c4f3_o.jpg
Once you have one corner out, gently pull out other corners
http://farm3.static.flickr.com/2584/4081979505_57f1bf589a_o.jpg
Now unplug the socket for the light switch .. push the locking lug to release. Put the dash panel safely somewhere. Notice the white clip in this shot ... some of these will come off when the covers are removed ... make sure you get them all and put them back onto the black lugs on the back of the panel.
http://farm3.static.flickr.com/2537/4082739312_3cf14b393b_o.jpg
Now you can remove the left hand screw from the ECU socket (note right hand screw can stay in place:
http://farm3.static.flickr.com/2457/4081979633_c2e058af84_o.jpg
Now gently pull down on the under dash panel to remove. Make sure you get all of the white clips again.
http://farm3.static.flickr.com/2761/4081979697_7cbe0b2560_o.jpg
Now remove the two screws that holds the heater duct in place:
http://farm3.static.flickr.com/2671/4082739572_1a3d2436e9_o.jpg
http://farm3.static.flickr.com/2583/4082739632_6e23343537_o.jpg
Now remove the heater duct ... it will take some manouvering to get past the clutch pedal.
http://farm3.static.flickr.com/2615/4082740064_9025deedd3_o.jpg
OK ... now you can remove the spring which make the clutch action easier .... I am sure this is part of the problem. Push the pedal down with yout hand, then put a large flat blade screwdriver under the edge of the spring and level off. Once the edges are out of the holes you can pull the centre out of the plastic retainer on the clutch pedal arm.
http://farm3.static.flickr.com/2436/4081980073_5c25a49642_o.jpg
Now drill a 1/8th hole through the clutch pedal arm just above the cut out for the plastic retainer. MAKE SURE YOU PUT SOME NEWSPAPER ON THE FLOOR SO YOU DON'T GET IRON TURNINGS IN YOUR CARPET.
http://farm3.static.flickr.com/2590/4081980401_07b7ee6578_o.jpg
Now remove the lower bolt shown with a 13mm spanner.
http://farm3.static.flickr.com/2487/4081980231_4e3031dfda_o.jpg
OK .. now it's time to make the bracket. Get some 3/4" light mild steel angle and cut it 150mm long. Then drill a 21/64th" hole 20mm in on end. Remember to keep the hole out far enough so that the head of the bolt can turn on the inside of the angle. Then drill a 1/8th" hole on the other end on the aposing side of the angle ... but as close as possible to the inside . Then cut along the same side 8mm in and 90mm long. This cut out is to accomodate the heater duct.
http://farm3.static.flickr.com/2779/4081980449_9f2cf42b15_o.jpg
Now you're going to need a retaining spring ... I bought a 9/16 x 4" x 0.047 from bunnings and with trial and kept cutting it shorter until it was perfect at 60mm long.
http://farm3.static.flickr.com/2630/4082739944_302614b512_o.jpg
Hook one end of the spring through the hole in the clutch pedal
http://farm4.static.flickr.com/3528/4082740228_d6a75a7c3c_o.jpg
Now put the heater duct back into position and put the left hand screw in loosly so that it still has movement.
http://farm3.static.flickr.com/2776/4081979945_fb1c4a9d3d_o.jpg
Now put the bolt through your bracket and put in place. This is a bit fiddly but not impossible. You can't put the duct back in if this is in first, and you can't get this in if the duct is fully in place without movement. Pull the bracket back as you tighten in, but make sure the end is not obstucting the hole for the white retaining clip. NOTE DO UP BOLT VERY VERY TIGHT.
http://farm3.static.flickr.com/2584/4081980563_bf30e5bd97_o.jpg
Now hook the other end of the spring through the hole on the bottom of the bracket. The duct has enough movement to keep out of the way, and the plastic below the bracket can be forced back to make this easier.
http://farm3.static.flickr.com/2632/4082740406_7e7bf14729_o.jpg
Now you can start putting it back together
put the screws back into the duct
http://farm4.static.flickr.com/3521/4081980767_a90c201451_o.jpg
Clip the under dash panel back in place
http://farm3.static.flickr.com/2482/4082739508_ee3b25ed66_o.jpg
Put the screw back into the ECO socket
http://farm3.static.flickr.com/2485/4082740528_e61a827209_o.jpg
Put the plug back into the headlight socket
http://farm3.static.flickr.com/2615/4081980877_9e99f248d2_o.jpg
Carefully clip the front dash panel back into place.
http://farm3.static.flickr.com/2499/4081980939_16137934ea_o.jpg
Done ... Now enjoy your non sticking, non slipping clutch!
It will be heavier than before... but not as heavier as a Textralia or high performance clutch. I got used to it within minutes.
well after reading the clutch sticking thread I have applied some of the advice from in there and added my own fixes.
Bottom line is that I did this last night, took the car out this morn and thrashed the crap out of it and NO PEDAL STICKING OR CLUTCH SLIPPING OR SMELL!!!
So I have pulled it all apart and started again taking pics as I went so I could share this with everyone. Dead easy ... less than 2 hours work.
Here we go:
Firstly gently pull out the front dash panel.
http://farm4.static.flickr.com/3520/4081979425_d45e90c4f3_o.jpg
Once you have one corner out, gently pull out other corners
http://farm3.static.flickr.com/2584/4081979505_57f1bf589a_o.jpg
Now unplug the socket for the light switch .. push the locking lug to release. Put the dash panel safely somewhere. Notice the white clip in this shot ... some of these will come off when the covers are removed ... make sure you get them all and put them back onto the black lugs on the back of the panel.
http://farm3.static.flickr.com/2537/4082739312_3cf14b393b_o.jpg
Now you can remove the left hand screw from the ECU socket (note right hand screw can stay in place:
http://farm3.static.flickr.com/2457/4081979633_c2e058af84_o.jpg
Now gently pull down on the under dash panel to remove. Make sure you get all of the white clips again.
http://farm3.static.flickr.com/2761/4081979697_7cbe0b2560_o.jpg
Now remove the two screws that holds the heater duct in place:
http://farm3.static.flickr.com/2671/4082739572_1a3d2436e9_o.jpg
http://farm3.static.flickr.com/2583/4082739632_6e23343537_o.jpg
Now remove the heater duct ... it will take some manouvering to get past the clutch pedal.
http://farm3.static.flickr.com/2615/4082740064_9025deedd3_o.jpg
OK ... now you can remove the spring which make the clutch action easier .... I am sure this is part of the problem. Push the pedal down with yout hand, then put a large flat blade screwdriver under the edge of the spring and level off. Once the edges are out of the holes you can pull the centre out of the plastic retainer on the clutch pedal arm.
http://farm3.static.flickr.com/2436/4081980073_5c25a49642_o.jpg
Now drill a 1/8th hole through the clutch pedal arm just above the cut out for the plastic retainer. MAKE SURE YOU PUT SOME NEWSPAPER ON THE FLOOR SO YOU DON'T GET IRON TURNINGS IN YOUR CARPET.
http://farm3.static.flickr.com/2590/4081980401_07b7ee6578_o.jpg
Now remove the lower bolt shown with a 13mm spanner.
http://farm3.static.flickr.com/2487/4081980231_4e3031dfda_o.jpg
OK .. now it's time to make the bracket. Get some 3/4" light mild steel angle and cut it 150mm long. Then drill a 21/64th" hole 20mm in on end. Remember to keep the hole out far enough so that the head of the bolt can turn on the inside of the angle. Then drill a 1/8th" hole on the other end on the aposing side of the angle ... but as close as possible to the inside . Then cut along the same side 8mm in and 90mm long. This cut out is to accomodate the heater duct.
http://farm3.static.flickr.com/2779/4081980449_9f2cf42b15_o.jpg
Now you're going to need a retaining spring ... I bought a 9/16 x 4" x 0.047 from bunnings and with trial and kept cutting it shorter until it was perfect at 60mm long.
http://farm3.static.flickr.com/2630/4082739944_302614b512_o.jpg
Hook one end of the spring through the hole in the clutch pedal
http://farm4.static.flickr.com/3528/4082740228_d6a75a7c3c_o.jpg
Now put the heater duct back into position and put the left hand screw in loosly so that it still has movement.
http://farm3.static.flickr.com/2776/4081979945_fb1c4a9d3d_o.jpg
Now put the bolt through your bracket and put in place. This is a bit fiddly but not impossible. You can't put the duct back in if this is in first, and you can't get this in if the duct is fully in place without movement. Pull the bracket back as you tighten in, but make sure the end is not obstucting the hole for the white retaining clip. NOTE DO UP BOLT VERY VERY TIGHT.
http://farm3.static.flickr.com/2584/4081980563_bf30e5bd97_o.jpg
Now hook the other end of the spring through the hole on the bottom of the bracket. The duct has enough movement to keep out of the way, and the plastic below the bracket can be forced back to make this easier.
http://farm3.static.flickr.com/2632/4082740406_7e7bf14729_o.jpg
Now you can start putting it back together
put the screws back into the duct
http://farm4.static.flickr.com/3521/4081980767_a90c201451_o.jpg
Clip the under dash panel back in place
http://farm3.static.flickr.com/2482/4082739508_ee3b25ed66_o.jpg
Put the screw back into the ECO socket
http://farm3.static.flickr.com/2485/4082740528_e61a827209_o.jpg
Put the plug back into the headlight socket
http://farm3.static.flickr.com/2615/4081980877_9e99f248d2_o.jpg
Carefully clip the front dash panel back into place.
http://farm3.static.flickr.com/2499/4081980939_16137934ea_o.jpg
Done ... Now enjoy your non sticking, non slipping clutch!
It will be heavier than before... but not as heavier as a Textralia or high performance clutch. I got used to it within minutes.