Clutch pedal is off, here are pics of spacer.

[kensmith]

Ok, I got the pivot bolt out and the clutch pedal spacer out. See pics of the spacer below. I am thinking the spacer is broken and badly worn? Would this be making the noise? Attached are 3 pics of the spacer and 1 video with sound of the clutch pedal noise. Let me know what you think. Also, clutch was a little hard to depress the pedal.

Video and sound of clutch when depressing the pedal:










Pics of the clutch pedal pivot spacer:

[majicwrench]

Bushing looks fine to me. Like I have said before, you really need a good idea of just where the noise is coming from BEFORE you take it apart.

[ventura ace]

I agree that the split bushing was made that way, and not broken. Now that you have it apart, clean everything up, lubricate (everything that moves or rubs against something else) with some grease that will stay there (not WD-40 or a thin viscosity oil), and put it back together. Put a little lube where the pedal fingers hole the clutch cable, also.

I'm betting your noise will disappear.

Alvon

[kensmith]

The bushings are paper thin. You think they are ok? The noise is definitely inside the car and sounds like the pivot area. Anyone have any measurements for the bushings? Ok, then I will use some white grease after I clean everything up and put it all back together. They are very dry.

[ventura ace]

Measure the OD and ID of the parts surrounding the bushing, and that should give you an idea of how thick the bushings could possibly be. You'd like to have at least a thou or 2 clearance. What do the measurements show?

Alvon

[kensmith]

Actually looking at pics from vendors, the bushings look the same. I cleaned everything up and used white grease inside and out of all the internal parts. Everything was dry so I have a feeling that was the problem. I will put it all back together today and see what happens. And when I say dry, I mean bone dry! There was only some small amount of black grit on the bushings.

[So Cal Mark]

once it's reassembled you can check for wear by attempting to rock the pedal from side to side. If those bushings are worn (they look normal) the pedal will have some play.

[kensmith]

once it's reassembled you can check for wear by attempting to rock the pedal from side to side. If those bushings are worn (they look normal) the pedal will have some play.

Well, greased everything with white grease, took me 2 hours to put it all back together. Still makes the noise but not as loud. How difficult to replace the clutch cable? If anything like taking the pedal apart and putting it back together, I am taking it to a mechanic. I am friggin sore and tired fighting that pedal!

[So Cal Mark]

it's much easier to replace the cable while the pedal is out. It's difficult to get the end of the cable into the pedal fork with the pedal in place

[kensmith]

it's much easier to replace the cable while the pedal is out. It's difficult to get the end of the cable into the pedal fork with the pedal in place

Great, I really don't want to go through that again. Can't the cable be slipped onto the pedal fork before you install the other end giving room to slip it in? Or make some kind of tool out of a coat hanger to grab it with?

[ventura ace]

Did you lube where the springs are attached? That can make a squeaking noise. Anything that moves, slides, rubs, etc. can make a noise from friction if not lubed.

Alvon

[kensmith]

Did you lube where the springs are attached? That can make a squeaking noise. Anything that moves, slides, rubs, etc. can make a noise from friction if not lubed.

Alvon

Don't have a spring for the clutch pedal, just the brake pedal. Clutch pedal comes all the way up just fine so I guess the prior owner figured he didn't need the pedal spring. I lubed every moving part so I ordered a new cable. I'm going to try and replace the cable without removing the pedal as I really struggled with the bolt and getting the bushings to stay in and line up. Still have a head ache from the job. So I'll be searching for tips on installing the new cable.

[So Cal Mark]

the clutch spring works both ways; it helps pull the pedal down once it gets over center, and helps pull up in the same fashion

[ventura ace]

As others suggested, I would keep trying to find the exact source of the noise before replacing the clutch cable. I know its hard to get your head in there to listen while you are pushing the clutch, but you need to try to do that. You can use a length of rubber or vinyl tubing as a stethoscope. Put one end in your ear and probe around with the other end until you find the noise getting louder -- this works very well!

It may be that not having the clutch spring at the pedal is causing the problem. Without the spring, there is more force on the bushing in the direction toward the firewall (the bushing is loose on the side toward the firewall, and all the load is compressing the bushing on the side toward your seat). With the spring in place, it pulls the clutch pedal pivot toward the seat, and would reduce some of the load on the bushing (maybe to the point where the load is either balanced or actually in the opposite direction. You might want to get one of the springs and put it in there to see if it makes a difference. You'll need the S-Hook and the spring.

Then again, maybe it's the cable, as you are thinking!

Alvon

[kensmith]

Matt sent me a spring but he didn't have the other part to it. Can someone give me a measurement and maybe I can make one. I did notice today the noise is almost gone so maybe it just took some time for the grease to work in? I also sprayed a little WD40 into the clutch cable. The noise is almost gone unless I press the clutch in very slowly.