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Old 03-15-2016, 08:28 PM   #1 (permalink)
Ecky
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Join Date: Dec 2011
Location: New Zealand
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ND Miata - '15 Mazda MX-5 Special Package
90 day: 39.72 mpg (US)

Oxygen Blue - '00 Honda Insight
90 day: 58.53 mpg (US)
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Help me fix my Insight

My wife was recently in an accident in our Insight, as is detailed in another thread in this section. I've replaced the broken suspension components, but there's a major obstacle to getting it back on the road that still remains: There's something wrong with the clutch.

At first, the car wasn't starting, and I couldn't figure out why. Turns out that when I was pressing the clutch pedal in (to the floor), the pedal was no longer pressing the clutch switch in fully:




Using my clutch bypass switch I was able to start the car, but the first time I tried to back it out of my garage, I discovered that the clutch is engaging waaaaay lower than it used to. I have to press the pedal all the way to the floor for it to disengage the clutch, and when releasing it, it's within the first half inch that the clutch fully grabs.

It doesn't look any different to me, and I can't see any stress lines in the aluminum indicating a bend, but the only thing that makes any sense to me is that the pedal, or perhaps where it mounts to, is bent. I don't have anything to compare it too though.

How far in is the hydraulic piston (?) supposed to go, when the pedal is fully depressed? This is how it looks now:

Out:


Fully in (pedal to the firewall):



Here are some more pictures of the pedals:








This is where the clutch pedal contacts the rubber stop on the firewall:




Any ideas? I don't want to buy a new pedal assembly, only to find it was something else entirely.

~

Also, I'm getting a LOT more vibration than I used to. Here's a video of me revving the car in neutral:

https://youtu.be/wEuEWyzpN0M

The whole car resonates at certain RPM.

I have no CEL, the engine seems to run properly and when I took it for a test drive around the block, it felt like it should, other than the vibrations. I gave a visual inspection and nothing in the engine bay is contacting the engine where it shouldn't, and all of the engine mounts are intact. I'm at a loss as to what's causing it.

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