Must be such a weight off your chest - congrats man!

Sent from my Nexus 5 using Tapatalk

Wuttttttt!!!!! You're the man. :bow:

Sounds very similar to the issue my 07 Si had. The CMC was the culprit in that case.

Ours wouldn't happen to be made by Aisin would it?

@BaeK @JB86'd @Target70 @whiskerbox

Okay, so here's the fix.

This bolt here, with the red circle around it, is too tight. It may be hard to locate at first. Look for the rod that you adjusted that goes into the master clutch cylinder. Follow that back until you find the large rod that goes perpendicular to it, going all the way to the clutch pedal. The assembly to hold the actuator in, that bolt there is too tight. Factory spec is 13ft lbs but it should be more around 8 ft lbs. I bought a nylon washer from lowes, not sure if it helps much. This will remove the popping noise. I can still hear some kind of noise, but it is much more subtle and not as loud as the obnoxious pop.

http://i.imgur.com/q89wu3C.jpg

http://i.imgur.com/TW6iV6h.jpg

The key is to not over tighten that bolt. Loosen it up a bit, and do a guess and check. Play and see if that causes it to pop. I think the nylon washer allowed me to make it a little tighter while still preventing the noise from happening.

If it is real loose, then the assembly will move around a bit. You want it right where it doesn't move around barely, and it doesn't make the noise

:cheers:

i watched your video and it annoyed me. i can't imagine dealing with that every day

it was very irritating. I would just turn up music loud. But when I was taking a coworker to lunch or something, and it was dead quite.. I was like... man, my new car, and it makes this awful noise..

I'm not entirely sure. It turned out to be the clutch assembly itself instead of the actual cylinder.

how to solve your problem: donkey punch coworker till he/she passes out

@trevorovert can't wait to get home and try this. I'll report back tomorrow night if it works for me. Thanks a lot man!

Same here!! I will try this tomorrow night when I put my retrofitted headlights on my car. Two birds one stone I hope!

Thanks for your hard work @trevorovert !

Yeah no problem guys. You should definitely tinker with it a bit, because you may get slightly different results, but that bolt is 100% the source of the noise.

Drove it to work today and didn't hear a single pop. I turned the car off and played with it a bit and could only hear minor noises now. I may loosen it a tad more. not concerned with it coming out at all, it still feels very sturdy even with much less torque on the bolt

I imagine you could probably remove the bolt completely, if you wanted.. not sure if it would put any more stress on anything else

Quick question @trevorovert :

Do I have to remove the cotter pin before loosening the bolt you mentioned above? Or can I go straight to the bolt and loosen it without doing anything prior to that?

Thanks.

just go straight for the bolt and loosen it