Clutch Pedal Travel Stopper (CPTS) Modification
 

Included in Kit:
1x Threaded Bumper
1x Black-oxide steel washer (0.125 inch thick)
3x Type 316 stainless steel washer (0.05 inch thick)
1x Serrated-Flange nut

https://farm3.staticflickr.com/2847/...18f96d8e_b.jpg

Tools Required:
9mm or 11/32in combination wrench (optional)


Instructions:
1. Locate the bracket holding the clutch pedal spring assembly and clutch pedal stop.

2. Carefully remove rectangular factory rubber clutch pedal stop by grabbing the sides and pulling out.
NOTE: Be careful not to use excessive force as this may damage the thin clutch stop.

https://farm4.staticflickr.com/3830/...6f0bebe9_b.jpg

3. The hole that the clutch pedal stop mounts to will now be visible, pictured below.

https://farm4.staticflickr.com/3741/...14a69248_b.jpg

4. The nut will have to be placed behind the bracket. It may be necessary to depress the clutch pedal to move the spring assembly back. While depressed, place nut behind bracket with 11/32in or 9mm wrench, and slowly release clutch pedal.
WARNING: It may pinch fingers, so it is advised to have some help to depress the pedal while installing.

5. Thread bumper with desirable washer configuration.
NOTE: It is not advised to use all 4 washers. Recommended configurations:
0 washers
1 thick washer
1 thick and 1 thin washers
Up to 3 thin washers
NOTE: It is recommended to have no more than 0.18 inches thickness (1 thick and 1 thin washer) to ensure the bumper stud has sufficient amount of threads into the nut.
 
6. Test to verify that the clutch pedal can be depressed to engage the engine switch.
NOTE: If the engine does not start, remove washers to achieve the proper height.
NOTE: You will have to adjust the 2 sensors mounted below the dash. The lower sensor that is more easily accessible detects when the clutch is engaged and may need to be adjusted when lowering clutch pedal when the gear display is enabled. The higher sensor, that is more difficult to access detects when the clutch is depressed to enable the engine starter. Both sensors are adjusted with 14mm wrenches.

7. When final height is set, wipe any grease off of the rubber bumper and use rag or towel to grip the rubber stop and tighten using 9mm wrench on nut.

8. Admire your work, and enjoy your CPTS!

https://farm3.staticflickr.com/2880/...7559a965_b.jpg

Feel free to message me for more information.

I got this kit from @JDKane527 and it fits into the bracket perfectly.

It was hard to shift into the gears unless I put extra pressure after the clutch hits the stopper to depress the pedal even more. I had the clutch pedal lowered 3 months ago so that it was either the same height or slightly lower than the brake pedal (don't remember, since I did the adjustment last year as well). I'm not sure if this is the cause of the problem or not.

I ended up chopping off about a fifth to a quarter of the bumper and I'm able to shift into gear perfectly now. The shifter is going into all of the gears like before.

The rubber is nice and dense inside, so I don't think it'll wear out any faster than when it had the outer layer.

http://i.imgur.com/VuUJQ3M.jpg

I'll have to get used to the shorter travel, though. Didn't give it enough gas a couple of times when shifting because I'm so used to letting off the clutch half an inch before giving it gas. Now that the bumper is there, I need to give it gas as soon as I let go.

It is a lot less tiring to shift now! Since I'm usually pressing the clutch all the way down, I don't need to extend my calf muscles as much anymore.

Where are you buying this stopper? I'd like to try this out.

Check your inbox

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Where to find this rubber stopper. I can't seem to find a stopper that can be tightened. Everywhere I see online just sell the rubber only.

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I just cleaned the hard stop with some acetone and used one of these little buttons. Works perfectly and I have 15 extra. :D

http://ecx.images-amazon.com/images/...BL._SY355_.jpg

What u use to get the felt to stick?

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They're probably self adhesive.

lol... top right corner of the pic.

Seriously though, it works perfectly. Even feels better than the rubber stop.

Terrible that this OEM rubber stopper is a POS

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If u have 15 extra that means you used 23 felt pads?

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lolol.... They were really thin.

My wife puts them on everything so we have a junk drawer half filled with opened packages.

...for the record, I only type "lol" if I actually lol. Good stuff. ;)

Nearly anything is better than the OEM rubber stop. It's soft thin rubber that degrades easily over time, and is accelerated by heat.

Ultramaroon, great solution using local hardware store supplies. You can dial in the stop height precisely by stacking the discs. I'd be worried about the adhesive degrading over time due to heat, but with so many spares in the pack, you can change them pretty often.

ELIM5? What's the point of this? (serious)

Mods yo!

The clutch pedal from the factory is allowed to travel beyond the point of engagement. At times when shifting quickly, the driver may depress the clutch well beyond the point of engagement and continually doing this will wear out the clutch pressure plate. This stopper reduces travel beyond the point of engagement, therefore reducing wear on the pressure plate.

It should be noted that this should not be used as a crutch for not being able to feel out the point of engagement. I find that I don't have to touch the stopper for shifting between gears for the way I have it adjusted.

Like other "feel" mods, this will change the way the car feels to the driver. Won't make your car any faster around a corner or drop panties.

I have to admit the felt works.

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Why not just remove the spring and lower the pedal? Removing the spring will allow you to feel the point of engagement much better. Lowering the clutch pedal to slightly above the brake pedal will also reduce throw so that the clutch engages right off the floor. You mentioned you had a lowered pedal, why would you do both?

I have removed the spring and swapped the clutch slave cylinder to the smaller diameter bore. The feel is definitely improved.

Before I used this clutch pedal stopper, I lowered the clutch pedal with the OEM rubber stop to where it engaged slightly above the floor. I found that over time as the clutch fluid boils, the engagement point goes lower to the point where you can damage the clutch since it doesn't fully disengage. Another side effect of this is that you may have to adjust the ignition sensor to even start the car. You may also have to adjust the clutch sensor for your cruise control and gear indicator display to work.

If I could do it again, I would not have lowered the pedal and would have just done the stopper. Less things to have to adjust and easy to reverse.

Really? There's no need to ever adjust the ignition sensor, but adjusting the clutch sensor is incredibly easy. I've pulled the spring and lowered ~15 cars so far, and have heard nothing but praise for the clutch mod. Considering how long our clutches seem to last, I wouldn't worry at all about fluid boiling, and it's not like it's very hard to readjust. Just seems silly to do this when there's something out there that's better that costs nothing.

How much of a difference did you think the slave cylinder made? Haven't done that, yet, but debated giving it a go. Really like the way the clutch feels now, though.

You will have to adjust the ignition sensor if your car won't start. The sensor is plastic for the most part and as you lower your clutch pedal to where its above the ground, you're making more contact with it than it was initially designed for from the factory.

Readjusting the clutch is easy and can be done over and over. Once the oem rubber stop is done, you'll just have the clutch lever hitting the metal.

The engagement point was difficult for me to feel with the Exedy stg2 clutch and the spring lever removed. I ordered the slave cylinder and it helped.

Everyone that has tried this rubber stopper, which is more than 20, has had improved feel and they had previously tried adjusting the clutch pedal height. Different strokes for different folks.

I've wondered about how it would work with a heavier clutch. Does the stg2 still fully engage right near the top? That's the only thing about the stock clutch that still bugs me. I'd like that to be a little lower with some leftover travel up top.

Options are always nice.

Mine doesn't fully engage right near the top, probably 1/4-1/3 of the travel. I have to push down about 2/3 of the pedal's full travel to disengage.

I'm torn between a couple ideas. The stock clutch is weak because either they just focused on minimizing pedal weight or there's some other limiting factor to be considered.

:laughabove:
Inspired by this, I looked for other skid feet pads made of rubber that might work better for me: https://www.amazon.com/gp/product/B00W9N2S7E/

https://i.imgur.com/qVSO0tC.jpg


The bump stop in the 1st post is just too thick.
These are square, and a perfect size to cover that square-shaped area. :)

Now I just need to dig up some #8 screws out of the tool chest to tighten it down (I bought the ones with 3M tape and no screws).


https://i.imgur.com/D2k9TLM.jpg

Looks good. The funny thing is that I posted my solution before I really understood OP's original intent.



Accidentally hijacked the thread.


https://media.tenor.com/images/41567...35f9/tenor.gif

Glad you found a solution to work for you. Have you tried out the bumpstop?
The thickness of the bumpstop by itself is at the limit of where you will not have issues with ignition and allows fully depressing the clutch enough for shifts. If you have lowered the clutch pedal height, then you may have to adjust it with the bumpstop.

The mounting plate on the car is not threaded, so a nut will be needed to secure your bump stop if you choose to bolt it down.

It's all good, the solutions are similar in that they provide a better bump stop compared to oem. There are multiple solutions to get the same outcome.

I'm just being a little picky, no problem with the your round bump stop. I like to sit back in chair a bit when I drive, so 1) I need the clutch to not fully press in as far as the factory bump stop, but 2) also not sit higher than the brake pedal when it's not pressed.

After switching out the clutch slave cylinder to a smaller one, and adjusting my clutch pedal to a more comfortable height (about even/ maybe a smidge lower than the brake), the square bump stop is perfect height for my setup.

If I could shorten the clutch stroke even more, the round bump stop would definitely work.

I like that square bumpstop idea. The round one doesn't last very long. Maybe some metal instead of rubber?

https://farm5.staticflickr.com/4816/...696c3a56_c.jpg

Metal will clunk.

Oh well, what's another clunk. ;) Kidding aside, the main point of this "mod" is to raise the stop point, not to provide cushioning. Well, maybe just replace the rubber every year, annoying as that is.

It's .. annoying clunk. These are no diesels, one has to use clutch frequently, when rowing through gears on MT. That's annoying clunk often.

BTW, i had this mod with similar round stopper. Relatively thin metal plate of pedal cut through this rubber bumper quickly. 2-3 weeks quickly. Currently i DIY made thinner but much wider (then even base, that stopper is attached to) stopper (made from round furniture anti-skid pad, that can be attached with screw). Longer contact area = will cut through less.

And main point of this mod is not so much as to rise clutch bite point, as reducing overly long dead travel till bite point, isn't it? It's simpler to do by adjusting pedal travel (and clutch sensor) imho.

I think that's what I said, raising the point where the pedal stops, i.e., no further travel. And no matter how much you adjust the pedal, it'll still travel all the way to the stop. This is not about bite point, but rather about eliminating that travel region where the clutch spring misbehaves, without having to remove the spring.

Where can I buy the kit?

You can buy all sorts of bumpers from here:
https://www.mcmaster.com/bumper-cushions

However, I still haven't found a durable solution. Maybe I'll cut down some polyurethane?

The felt pads and rubber pads on Amazon are too soft imo.

As i've mentioned before. Try for bumpstop something of larger & flat area. If area of touch between pedal plate and bumpstop will be few times wider, proportionally it will cut through less/last longer, even if of same material and pushed against with same force / same frequency.
My current "bumpstop", flat furniture leg cushion in ring/washer shape, around 1 1/2 inch in diameter, with hole in mid for screw, lasts for me already for around two years.
Used for it screw from "desintegrated" bumpstop mentioned in this thread (as for me it also didn't last long before it got cut through), and sticked above this stopper thin felt.