From what I understand, both the clip and pedal are plastic, and wear out against the master cylinder rod... Poor design IMO, but we're stuck with it unless somebody develops a metal clutch pedal for the ION... Actually if I had a good pedal, and some time with metal cutting/machining tools, I'm sure I could come up with one, but the market is limited at best...

 

True. market would be limited, because people are to lazy to drive a standard in general.

 

you HAVE to know they found out in longevity testing that this happened---or they never bothered testing it....

And the clutch pedal can't be plastic.....really?

 

Its metal. But the connecting pieces are plastic. Youll see when I take a picture tomorrow.

 

thank you


Hell, use a wad of duct seal (no not duct tape) to build up the diameter of the ball, then put a small piece of trimmed sheet metal against the pedal where the ball sits up against it but form the rest of it to match the shape of the ball. Wire the pedal to the ball with 24 gauge wire, etc going around the pedal front, back behind the ball, around the master cyl shaft a few times, and back around the pedal. Since the ball must pivot in place, you can't cinch it in there--it needs some play--but you should be able to figure that out by trial and error. As long as the wire does not get too loose the ball should stay in as the 2 wearing surfaces are now isolated and the clip has been replaced by the wire. The sheet metal serves as a sliding surface against the built up ball so there should not be any issues w smooth pivoting. If you pack the duct seal tight enough it should not compress very much more with time.

 

 

Bump, still have a lot of parts from an 04, 05, and 07.


Let me know what you need.

 

bumppp