My 2009 wrx's clutch has been squeaking since I bought it this winter. I admit I haven't been keeping up with subaru stuff online, so I just thought it's a squeak, no big deal. Well it went from a squeak to a popping sound. So I've just recently discovered there is a whole firewall spot-weld issue. Looks like all six spot welds are broken on mine. The clutch is still functioning properly, just making a popping sounds every few times I depress the pedal. Anyway, most of the info I'm seeing online is out of date or people fighting warranty issues. I'm very far out of warranty, so what's the accepted way to fix this? Some people are just putting bolts in for the top two spots. Others are re-welding, but I've read the welds will just break again... Anyone here have experience with fixing this issue and have any advice? thank you
When I had a weak clutch issue in my 03 recently my searching returned a ton of results about your issue. Read into that just cuz and it seems like everybody that fixed it "properly" had to pull the whole dash assembly out to get at the brackets. Long story short, best of luck to ya.
Hey Joel!!!! I haven't experienced this as i am still in the bugeye. But would self tapping metal screws be an option?
That's about the best repair I can imagine without pulling the dash out. The rivets will pull the pieces back together. You could also drill a few hols through only the top layer and use them to make new "spot welds" with a welder, but you'd really want to do the rivets first to get everything tight together again.
Yeah, that's probably worth a shot. If they don't hold I can take the dash apart and drill those out to 1/4" and put some bolts in. Thanks.
09 here I did get a recall notice for the issue that you describe. I have not taken it in yet to have this inspected. I'am sure there will be no cost on a re-call item that effects the safety of the car.
I got a letter from subaru saying two things. 1. They were extending the original factory warranty by some small amount and would reimburse people who already paid to have this fixed. 2. The would do a free inspection to see if you had the problem. I'm well outside of even their extended warranty period so after the free inspection I'd still have to pay for the repairs. I have not gotten any recall notices for this car, but I should probably go search and see if anything comes up for it. Thanks.
If you had the available material under there to drill 1/4" holes right away, I've got access to 1/4" stainless, structural rivets and a gun to pull em. Would save having to somehow hold a nut on the back.
I know the top two welds would have clearance to do that, and some people are saying bolting those two are enough to fix it. I gotta look a bit deeper to see of the lower four would have clearance for that. What do you charge for your services?
Yeah... I've had this same issue for a while now. I was told this is a recall. I'm hoping that's true.
Haha. Do you have a compressor at your disposal? I can get the rivets and gun for free, would just have to be on a weekend. The only inconvenient thing is I'm in Owatonna. However, seems like we're going to/through the cities every weekend lately. Now that I think about it, I've got a portable air tank too. Can only assume it'd be enough to pull a handful of rivets.
Maybe I can provide the compressor, tools and space. I need the work done too. I'm in Savage. 4 or so miles from Burnsville center.
So I have a relatively recent squeak in my clutch pedal as well. Assuming it's something similar to this, my warranty will cover it, right? This can't possibly be considered a wear item.
I had the same problem with 09 WRX. I had to have a bracket welded in. I let the problem go for longer then I should have. It started to make a popping noise and the whole clutch/brake pedal assembly was moving every time I pushed the clutch in. That warranty extension is a joke in my opinion. Defyant MotorSports here in La Crosse did a great job on my WRX.
I have a compressor, it's small, but big enough to run my impact wrench or a framing nailer, etc. But I'm also on the north side of the metro, so a little further away. Otherwise, I might look into some sheet metal blind fasteners, some of them look fairly strong.
Not sure on your exact location, but north of the metro is usually where we go. Been in the Cambridge/Isanti/North Branch triangle for the most part, even a bit farther north as well. Will be coming back up again soon to continue on a side job. Could time it right and wouldn't be an issue at all.
Ok, cool. I'm in Arden Hills, close to Highway 96 and Lexington. This coming weekend, the 25th and 26th, is probably the only free time I'm going to have. If that works, awesome.
To follow up. I got a pneumatic gun and put in six 1/4" steel rivets. I do not have a lot of confidence in this fix lasting. It was only after the last rivet that the popping noise with the clutch pedal stopped. At least I didn't make things worse, the spot welds were completely broken free before I started. I put four of the rivets in the original broken spot weld locations. And the last two I put directly above and below a broken spot weld (bottom row, right side in the picture). In one of those locations there was only one layer of sheet metal (lowest bottom right rivet). There were no issues with access space for drilling or using the pneumatic riveter though.
does your firewall flex? lots of others say theirs did. im going to look at my welds this week if they are broken i will be doing the same fix but i wont be able to tell if the wall flexes without looking at it with the pedal pressed wonder if another piece of steel on the non cabin side would strengthen it up?
I assume it was flexing, but I never watched it while someone was pressing the clutch or brake. The general area where the spot welds are isn't very flat, so putting an extra piece of steel in there would be tricky, but I'm sure it would help. The clutch pedal feels a lot better today after the fix. It feels really solid again. I hope the fix will last a while. If not I'll disassemble the dash and put bolts in place of those rivets.
After a call to SOA and then Walser Subaru, I brought my car in for a visual inspection. The inspection is $105. BUT... they can do a visual of one part without disassembly. If that shows movement, they can proceed if SOA wants to pay. Mine moved, they paid. I'm very happy with the process and how Walser took care of me. SOA paid for it all. The clutch pedal doesn't make any noises now. So weird... I got used to a click every time I pushed the pedal. Walser didn't actually even do the work. They sent it out to the body shop where the dash was completely removed as well as the wiper assembly and cover. A weld was run across the top of the clutch assembly then the welds were all drilled out and re-welded. Then painted. Problem solved.
I watched them do a bit of the troubleshooting. When they pressed the brake and clutch at the same time, the firewall would move almost a half inch. I was shocked. I think I might look into a brake booster brace.
I am also having the same issue now. I had Bikerboy put in a stage 1 HD Exedy clutch and shortly after my clutch pedal began to creak... I am sure the brake pedal is also moving when I press the clutch in. What year is your car? Mine is probably to old for SOA to cover it.
2008 They asked if it had been modified or if the clutch was aftermarket. They said that a stiffer clutch or one that's wearing out will cause this issue.
If I recall the recall notice correctly, I think they will only reimburse out-of-warranty owners (08's, etc) if they already had work performed during the valid warranty period, but had to pay out of pocket at the time. You might want to double check the notice that you should have gotten in the mail...
I bought my car used last year, no warranties. Would anyone on here have experience and be willing to help me fix it?
