Opinions on clutch pedal assembly rebuild

[under50k226]

My car’s clutch assembly is coming out today. Its all loose but on my car has cruise control so the throttle cable is preventing me from taking out the clutch cylinder all the way preventing final removal. Anyway…I got this item with the bronze bushing option.


https://www.extremepsi.com/store/product.php?productid=26214&cat=0&page=1



In addition to installing these parts and considering my car’s modifications; should I attempt to get a master welder friend of mine to complete the weld presented in the following illustration provided by dsmtuners member rsymple in his thread concerning the same subject

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Or put it back together with the new parts installed and let it rip??

 

[kchaazz]

Put it together and weld the shite out of it. Itll wear out pretty quickly otherwise, especially if you have a clutch with a heavy pressure plate. Trust me, Ive done the pedal assembly swap far too many times and personally, if given the choice between pulling the pedals and pulling the motor and trans, Id choose the latter every time...

 

[Paul@RTM]

Itll wear out pretty quickly otherwise,

This. If you take a good close look at the brand new pedal components, you'll understand why these things eventually wear. The lever arm has a stamped out hole that is being asked to fit precisely on the matching shaft. Not going to happen. It's starting to wear the first time the pedal is pushed. It's simply a bad design. Mitsu must have realized it since the 2g's have a completely different setup. Point is, even a brand new pedal assembly should be welded. Otherwise, it's a perpetual motion machine of worn out components.

 

[under50k226]

Thanks guys!

 

[under50k226]

Was able to get the welding done thanks for a friend at Jacks, thoughts?

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Sadly; I noticed my clutch master cylinder gasket looks like hell.

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Off to NAPA, I guess.

 

[under50k226]

Didn't think the original weld did enough so I had it redone by and old friend.

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As you can see its attached to the arm directly. It shouldn't be able to rotate out.



Sadly, I've misplaced the gasket shown above - what should I do?

 

[bastarddsm]

I vee out the bracket. I also cut open the assembly and bend it out of the way for better welding access.

 

[under50k226]

I vee out the bracket. I also cut open the assembly and bend it out of the way for better welding access.

A little over a third of its welded together well; you do not think that will hold together for quite sometime?

 

[bastarddsm]

Nope. As much as it sucks to take out you need to do as good a job as possible.

 

[under50k226]

By modifying it in a way never covered in any of the online literature? You must have had a weld brake on you.

Every side exposed was welded together while the spring was engaged; I haven't read about anyone else cutting and bending their assembly to weld the arm and zbar all the way around the hole.

 

[bastarddsm]

Mine never broke, but pedal welds brake all the time. Ever think that just because it is taken as the gospel, doesn't mean it is?

 

[under50k226]

Gospel??? Simply put; these cars were built since 1989 – it’s logical to think that if cutting the assembly were part of the service requirements we would have heard about it by now; at least referenced on some part of one of the various DSM forums. But this is the first I’ve ever heard of anyone doing it.

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I just simply think that these welds will hold it together fine, and I’m surprised that someone would cut the assembly and bend it apart to weld the other half of the bolt. I’d love to hear from someone who’s welds have failed – I’d image it was barely welded or just the bottom washer and nut were welded like I had them do it at first. Its my first time doing it and more people will have to do it to save their cars too. I just want to contribute as much info as possible.