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  #1  
Old 29-06-2007, 05:03 PM
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Default Polars DYI- Removing empty/dead clutch pedal travel

With my new button clutch and 2800pound pressure plate setup the only part of my clutch pedal travel that bites is the last 4cm of travel.

There was an additional probably 9cm behind this. So that when I pressed the clutch all the way in it was almost touching the carpet.

With my short shifter gearstick this mean that I could always change into the next gear much faster than I could depress clutch and release which made for annoying shifting.

THE FIX!!!!! Simply remove 1.5cm-2cm of clutch pedal travel by installing a larger stopper in the place where the factory has installed a tiny stopper.

The factory stopper is so small that it does not even make contact with the clutch pedal at all.

Step 1.

Get a thin long bolt and some nuts. And screw enough nuts onto the bolt so that the bolt end section now is about 1.5cm tall.

Step 2.

Now simply remove the white factory rubber stopper with your fingers and you will see a hole.

Step 3.

Place bolt stopper into hole and screw a nut from other other side.

FINISHED.

You should now have a bolt sticking out of the factory stopper position and when clutch pedal goes down it stops against the end of the bolt 1.5cm higher than it used too.

Took it for a wrap around the block and gearchanges are much easier without having to put my foot through the bottom of the car and they are faster and BOV does not open as much.

NINJA CHANGES!

Comments or suggestions welcome.
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  #2  
Old 29-06-2007, 05:15 PM
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Please don't post crappy phone pics!!
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  #3  
Old 29-06-2007, 09:41 PM
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Quote:
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Please don't post crappy phone pics!!

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  #4  
Old 29-06-2007, 10:07 PM
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Heres a better idea..

Learn 2 drive and dont depress the clutch pedal ALL the way down, only enough for it to engage/disengage for the same effect. Something you should pick up within ~2 mins of driving any car.

"And the BOV does not open as much"

Its open for a shorter period of time.. quicker change means your back on boost sooner. Nothing to do with your stopper.

Depending on the material used on your button clutch.. when this wears down and the friction point goes further and further down the pedal. This COULD be a problem in the long run.

I see what you have attempted to do.. but i wouldnt exactly call it a mod :P
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Old 29-06-2007, 11:08 PM
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there is freeplay there to stop the clutch release bearing always being in contact with the clutch causing it to wear out quicker, but it is your car
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Old 30-06-2007, 08:57 AM
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If your master cylinder is prevented from returning fully (as it appears your is) the charging port is not opened. This means that fluid cannot "re-charge" the cylinder after one pump. So, when your clutch wears slightly and requires a little more fliud you'll end up not being able to select any gears.
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Old 30-06-2007, 12:09 PM
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Yeah but mine had MILES of clutch pedal travel. I have only just shaved off the last 2-2.5cm of travel.

If I have any gear selection issue at any point I shall just take the bolt out in 5 mins. As for the clutch I shall just see how it goes but it is miles easier to drive now.
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Old 30-06-2007, 12:23 PM
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Doing this mod = Time and Effort

Learning to drive properly = Free.
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Old 30-06-2007, 01:51 PM
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or you "could" adjust the pedal. But hey that would make sense.
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  #10  
Old 30-06-2007, 01:53 PM
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Quote:
Originally Posted by scary
or you "could" adjust the pedal. But hey that would make sense.
How is that done? Mine only takes up in the last quarter of release too...
shits me right off.
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clutch, dyi, empty or dead, pedal, polars, removing, travel


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