Welded clutch pedal assembly still has play

[turboAWDfanatic]

I've pulled my pedal assembly TWICE. Once to replace arm/lever with brand new Mitsu OEM parts (including new bushings). Still had free-play after that (the type where you can lift the pedal up with your toe after you've pressed the pedal down to the floor).

I pulled it a second time to weld the brand new parts together. I also had the factory welds on the assembly reinforced to prevent flex.

After all this I put the assembly in, pushed the pedal ONCE, and I've still got an inch of freeplay at the top. With the adjustment rod threaded a little ways into the pedal clevis the clutch pedal rests lower than the brake pedal and I have to screw the cruise switch all the way in.

I've been reading threads on 1g pedal wear for hours and can't find anything beyond what I've already done to solve the problem. So...besides the lever, bushings, and flex in the assembly from old welds, what else can cause excessive freeplay???

Thanks

 

[turboAWDfanatic]

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You'd probably be better off searching or starting a new thread, and fyi the mods here frown on thread bumping.

I don't have any part numbers handy but you can find the pedal and lever at Diamondstarmotorsport.com - Mitsubishi Eclipse, Eagle Talon, Plymouth Laser, Dodge Neon SRT-4 (though their website has been down) and also at Mitsubishi Turbo Performance Parts from Mach V Motorsports

Or, call the mitsubishi dealership and ask. That's where I found the best price on pedal/lever/bushings