It's great when my greater issues boil down to little annoyances

So I'm wondering what's up with my clutch pedal. It's well greased and seems to move freely without binding. When I depress the pedal, it moves smoothly. If anything, I can hear the very faint sound of the return spring stretching out -- I suppose slipping in its mounting holes. Then when I let clutch pedal back out about half way, there's moderately loud click/pop that I can feel with my foot. I've spent some time with my head under the dash, trying to figure out the source of the pop, but I don't see anything.

Is this a common problem? If so, what's its cause?

I'd check for wear in the clevis, the pin itself and the down arm on the clutch pedal. After a couple of decades of work that interface is a little less than pristine. I've had to weld up and re-establish holes and replace the pin just for that very reason......

Not a whole lot different than door hinges.

Also, Sarah, Check the indents that hold the return spring on the pedal and the pedal box. They can get worn. Mine squeaks when it wants a shot of grease...nice of it to tell me.

Cheers, Mike

Edited December 1, 201014 yr by Pop's Z

Thanks, guys! I was afraid it might be something like that. I hate working in that area! I might feel a bit differently if I were an 8 year old kid, but I can barely get my arms up in there! Groan....

You might be able to fit some semi circular nylon bushes to each end of the return spring.

Most modern cars have just that.

They prevent the spring from wearing grooves in the anchor points.

But my money is on a well worn clevis pin or clevis as mentioned.

There is probably a flat or grooves worn in the pin that causes the annoyance:rolleyes:

Not difficult to check, just remove the retaining pin and slip the little sucker out.

Odd--I've just started noticing the exact same behavior in my clutch pedal.

Nissanman, it's definitely not the anchor points for the spring that causes the pop. I guess the clevis pin makes sense. Does the push rod just pull out of the clutch master (i.e. with nothing else attached)?

FirstFruits, I'll definitely report back what the problem is that I find, but I don't know when I'll have time to get to it. Lots of irons on the fire.

Don't try to remove the clutch master rod, it is usually held in by an internal circlip.

The clevis pin itself should have either a split pin or an "R" clip through it.

Just remove that and you should be able to slip the clevis pin to one side and remove it.

Thanks, guys! I was afraid it might be something like that. I hate working in that area! I might feel a bit differently if I were an 8 year old kid, but I can barely get my arms up in there! Groan....

Have another kid.:stupid:

Thanks, Nissanman! That diagram helps a lot.

Ztrain, the thought had occurred to me.

Drum roll please....

And the winner is.... a worn clevis and/or pedal arm hole!

... not that I took it apart, but I could feel where the pin had worn an oblong hole in it that would pop if I pulled it the right way.

The obvious solution is to pull the pedal out, drill a larger hole through the pedal and clevis, and fit a larger pin. Anyone got an 8-year old who wants to earn some money?

BTW, Nissanman, I'm guessing you have right-hand drive in your Z. That would make working on the clutch pedal a LOT easier. I'm just not a good enough contortionist to cram my hand into that small space, shine a light where I'm working, and actually crane my neck beside the kick panel far enough to see much. Removing the clevis is easy, but removing the pedal could be more challenging. It looks like the easiest approach might be to pull the brake/clutch pedal assembly by unbolting the masters, removing a bolt under the dash, and dropping the whole thing down. But I won't be getting into that for quite a while. Maybe the noise will go away before then!

Anyway, thanks guys! At least now I know what the problem is.

Ztrain, the thought had occurred to me.

Wanna go halves?

Sorry-couldn't resist.

BTW-ONE of the bolts that holds the pedasl in( i forget which one) has REVERSE threads.

Edited December 5, 201014 yr by Z train