Saturn ION: Worn-out Clutch Pedal Fix

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gord888
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Joined: Sat Oct 28, 2006 1:20 am
Location: Milton, Ontario
 
by gord888 » Sun Nov 20, 2016 10:13 pm
There's a lot of posts on the internet about worn out clutch pedals on the Saturn ION. This is because - for reasons that defy logic - the clutch pedal is made of plastic and eventually disintegrates against the plastic ball at the end of the clutch rod.

You have a couple choices
1) you can either replace the pedal (which from what i've read is a royal pain).
2) Use the design below and build a bracket and rod-end design that won't fail so quickly. (installation doesn't require removing anything)

Disclaimer - i'm not an mechanical engineer. I'm a software guy... so the design below works, but definitely has room for improvement. All the "fabrication" was done with craptacular household grade tools and stuff you can get at Home Depot / Canadian Tire / Princess Auto. I have no guarantee (implied or explicit) that this will work for you.

There are some picture below - but the PDF for everything is here:
https://drive.google.com/file/d/0B81BoU ... sp=sharing

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