Clutch switch problem

Pete_89T2 · 07-02-2012, 01:53 PM

Yesterday during a shift I heard a "snap" sound down near the pedals and noticed that when shifting after that, I could hear a "click" sound every time I depress the clutch. I found a bunch of pieces of brown plastic in the footwell by the pedal, and it appears it was from some kind of plastic bearing surface that was once pressed into a hole on the metal clutch pedal assembly, and the plastic plunger piece of the clutch switch was supposed to ride against it.

The "click" sound is from the clutch switch's in & out motion being all cocked up without that plastic bearing surface on the pedal. It now bends a bit, and at the end of its travel it pops thru the hole in the pedal (the click) that the plastic bearing surface used to be in, putting the plunger at an odd angle - this can't be good for the switch.

My guess is the broken plastic piece was once cam shaped to allow the the switch plunger to ride in & out without flexing in any other directions. Hopefully I can still buy this part from Mazda without having to buy an entire pedal assembly. If not, I may have to get creative and fabricate something. To that end, I was wondering if someone can snap a picture of their clutch switch plunger & pedal area. If I knew the shape of this thing, I might be able to fabricate something out of epoxy putty.

RETed · 07-02-2012, 03:19 PM

It's just a plastic plug that goes into a hole in the clutch switch arm.
When mine broke, the idle got all funky - it idled a little higher than normal.

I ended up gluing a use leather cue tip I had laying around to just plug the hole.

-Ted

Pete_89T2 · 07-02-2012, 03:42 PM

Cool, should be an easy fix then. I have some extra felt stick-on furniture foot pads used to protect wood floors laying around somewhere, will give that a try.

07-02-2012, 01:53 PM	#1
Pete_89T2 Lifetime Rotorhead Join Date: Apr 2010 Location: Elkton, MD Posts: 874 Rep Power: 15	Clutch switch problem Yesterday during a shift I heard a "snap" sound down near the pedals and noticed that when shifting after that, I could hear a "click" sound every time I depress the clutch. I found a bunch of pieces of brown plastic in the footwell by the pedal, and it appears it was from some kind of plastic bearing surface that was once pressed into a hole on the metal clutch pedal assembly, and the plastic plunger piece of the clutch switch was supposed to ride against it. The "click" sound is from the clutch switch's in & out motion being all cocked up without that plastic bearing surface on the pedal. It now bends a bit, and at the end of its travel it pops thru the hole in the pedal (the click) that the plastic bearing surface used to be in, putting the plunger at an odd angle - this can't be good for the switch. My guess is the broken plastic piece was once cam shaped to allow the the switch plunger to ride in & out without flexing in any other directions. Hopefully I can still buy this part from Mazda without having to buy an entire pedal assembly. If not, I may have to get creative and fabricate something. To that end, I was wondering if someone can snap a picture of their clutch switch plunger & pedal area. If I knew the shape of this thing, I might be able to fabricate something out of epoxy putty.

07-02-2012, 03:42 PM	#3
Pete_89T2 Lifetime Rotorhead Join Date: Apr 2010 Location: Elkton, MD Posts: 874 Rep Power: 15	Cool, should be an easy fix then. I have some extra felt stick-on furniture foot pads used to protect wood floors laying around somewhere, will give that a try.