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My clutch pedal is about 3" below my brake pedal. Aside from looking dumb, I'm assuming it's bent.
You guys have the same issue on yours, or is your pedals the same height?
I have to measure the master cyl travel tomorrow, but I'm guessing it's not pushing all the way. The pedal back will crash into the FW. Maybe it's just me, but I doubt it.
If it engages and disengages fine, then what's the big deal. You say it hits the firewall.....of course it's going to hit the firewall if you push it far enough. Obviously I can't see it, but IMHO if it ain't broke, don't fix it.
The problem is the design, as Matt suggested. The pedal doesn't have an integrated stop. So if you keep wailing on it, it will eventually bend until it crashes into the firewall. Poor design.
If it engages and disengages fine, then what's the big deal. You say it hits the firewall.....of course it's going to hit the firewall if you push it far enough. Obviously I can't see it, but IMHO if it ain't broke, don't fix it.
I think maybe you don't understand the design of the system. It's not supposed to hit the firewall. If it does it has bent.
The problem is the design, as Matt suggested. The pedal doesn't have an integrated stop. So if you keep wailing on it, it will eventually bend until it crashes into the firewall. Poor design.
-- Joe
Ok, I guess I wasn't looking at this right.
I was trying to figure out how the pedal arm could bend, but I didn't realize there was a stop on it.
So I pulled it all back out today, and made a jig. It looked way worse than it was, realistically it was about 1.6" bent, and a little over to the right (almost hit the brake pedal).
So I pulled it out, and did some magic in the hydraulic press. Now its about
1/4" above the brake pedal.
Another thing to notice, on the second bend of the pedal, it isn't reinforced. This is where mine was bent, and I'm sure others as well. I took some flat stock and welded it to the back side of the bend. Hopefully
this will keep it in spec.
The rod travel looks correct now. I'm convinced this is 90% of the problems folks experience with the clutches on the ZF6 cars.