Clutch Pedal SNAP OFF 8 Year Warranty-Recall ~~~
#876
Extraordinary Engineering
It looks to me like metal fatigue in the bracket causes a tear near the bolt which then causes the spot weld to break.
So the main failure mode seems to be metal fatigue.
Welding will support the metal and reduce fatigue but additional support should be added near the bolt holes.
The aftermarket brace will also transfer the load away from the thin metal to prevent fatigue.
Electronics for me.
Semiconductor Test Engineering
![EEK!](https://www.rx8club.com/images/smilies/eek.gif)
Last edited by DarkBrew; 09-01-2010 at 05:00 PM.
#878
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lets pretend that the sheetmetal used is not too thin(just like mazda did) and go back to this question directly...
and what would happen to the pedal if, while being flexed these spots give way?
#879
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Just wondering one thing...
Mazda thinks the problem arises from improper tightening sequence. I've seen enough stuff go bonkers from improper sequence, so that's plausiable.
So...does anyone know what the proper tightening sequence is for the bracket? And would it make sense to loosen the bolts and re-tighten in the right sequence?
Ken
Mazda thinks the problem arises from improper tightening sequence. I've seen enough stuff go bonkers from improper sequence, so that's plausiable.
So...does anyone know what the proper tightening sequence is for the bracket? And would it make sense to loosen the bolts and re-tighten in the right sequence?
Ken
#881
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Pretty good intuitive stress analysis for a non mechanical engineer.
This is what I said a long ways back.
These spot welds are not intended to hold this bracket together. They are simply there as a tack to hold the back piece to the front for assembly. In fact you can cut these welds off and throw the back piece away. Replace it with two long bushings for the proper separation to the firewall. Bolt everything back up properly and you shouldn't notice much effect of the change.
#885
Extraordinary Engineering
School of Reality plus good troubleshooting skills.
Quite right.
Next person to weld a bracket please add reinforcement where it's needed; at the bolt holes as pointed out on the previous page!
#888
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Just wondering one thing...
Mazda thinks the problem arises from improper tightening sequence. I've seen enough stuff go bonkers from improper sequence, so that's plausiable.
So...does anyone know what the proper tightening sequence is for the bracket? And would it make sense to loosen the bolts and re-tighten in the right sequence?
Ken
Mazda thinks the problem arises from improper tightening sequence. I've seen enough stuff go bonkers from improper sequence, so that's plausiable.
So...does anyone know what the proper tightening sequence is for the bracket? And would it make sense to loosen the bolts and re-tighten in the right sequence?
Ken
You tell the tech how the BEEP does he / she think there was 3 generations of Rx7 with no BEEPing clutch bracket problems and you don't want to hear any stupid talk about sequence. It's cheap materials & design period.
#889
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I can picture assembly line workers taking that kind of shortcut. Especially on a Monday morning or Friday afternoon.
Still Mazda's fault, of course.
Ken
#890
Just wondering one thing...
Mazda thinks the problem arises from improper tightening sequence. I've seen enough stuff go bonkers from improper sequence, so that's plausiable.
So...does anyone know what the proper tightening sequence is for the bracket? And would it make sense to loosen the bolts and re-tighten in the right sequence?
Ken
Mazda thinks the problem arises from improper tightening sequence. I've seen enough stuff go bonkers from improper sequence, so that's plausiable.
So...does anyone know what the proper tightening sequence is for the bracket? And would it make sense to loosen the bolts and re-tighten in the right sequence?
Ken
Cuz people don't even look at their bracket (or touch them) until the thing snaps. guess who tighten those bolts up in the first place ?
And did I tell you guys that we're not the only one experiencing the same issue. Even people in the far east, RHD, Still getting the same issue. So its not just a LHD thing, its universal.
I agreed with 1/2 of what VashGS said, material is f-ing cheap, design was alright. if they would invest another what, maybe 10 bux extra for each bracket, just to make the metal a little bit thicker. would probably prolong the life of the thing by 2x.
Mazda is just full of **** on this one, they still gotta suck that 8 year/100K warranty up.
Last edited by nycgps; 09-01-2010 at 10:10 PM.
#892
Registered
No matter what the reason, it's their fault. If it's really improper tightening, then they screwed up on training or assembly procedure. That's as big a part of making a product as the materials they use.
Anyway, I can now relax about the squeak in my clutch pedal...the one that goes away every time it's at the dealer. It has four more years to show that it's benign or to fail.
Ken
Anyway, I can now relax about the squeak in my clutch pedal...the one that goes away every time it's at the dealer. It has four more years to show that it's benign or to fail.
Ken
#893
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A clutch pedal should NEVER fail like these. Not in 10 years. Not in 20 years. Certainly not "en masse".
I never had a car in my life where this was an issue. Ever. Haven't even heard about one with any other car, but I may just be lucky (or ignorant).
Provided they will indeed make the announcement about this being covered under warranty. The way they are feeding BS to NHTSA and try to wiggle out of it belittling the issue is anything but reassuring about their stance of real willingness to "suck it up".
I never had a car in my life where this was an issue. Ever. Haven't even heard about one with any other car, but I may just be lucky (or ignorant).
Mazda is just full of **** on this one, they still gotta suck that 8 year/100K warranty up.
#895
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Autoblog has reported on it before http://www.autoblog.com/2009/10/06/r...da-rx-8-clutc/
#896
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They've reported on it before, but now it's more or less a recall according to the NHTSA. Big difference. I say more or less because they're just extending the warranty on it so it's not a true recall. That's a pretty cheap **** way to handle it though. It's the same pedal in each car so the chances of a pedal failing are always there. Considering the clutch pedal breaking completely disables the car it's bullshit that they'd just extend the warranty and hope you never come in. Most will only come in after it's too late, and after it's too late is when it becomes a huge safety concern.
My clutch pedal is in the beginning stages of failure as of earlier today. It's moving left and right and making some god awful noises when I push down on the clutch. I planned on just parking the car for a week before I did anything about it anyways so hopefully Mazda acts up while it's just sitting in the garage and I can get this done for free!
One little observation though. I wonder if Mazda isn't announcing anything yet because they don't have a replacement part to install on the car? If they install the same exact one the failure is likely to happen again after all.
My clutch pedal is in the beginning stages of failure as of earlier today. It's moving left and right and making some god awful noises when I push down on the clutch. I planned on just parking the car for a week before I did anything about it anyways so hopefully Mazda acts up while it's just sitting in the garage and I can get this done for free!
One little observation though. I wonder if Mazda isn't announcing anything yet because they don't have a replacement part to install on the car? If they install the same exact one the failure is likely to happen again after all.
#897
Autoblog has reported on it before http://www.autoblog.com/2009/10/06/r...da-rx-8-clutc/
Now they have the conclusion (sort of)
#899
a lot of people thought "its normal" and replaced it elsewhere (come on, who wants to do it at dealership, they will probably charge you 400 bux for it, its a 10-15 minute job)
Thats why a lot of "service manager/Mazda themselves" said "first time seeing it/effecting 1% users only"
Thats why a lot of "service manager/Mazda themselves" said "first time seeing it/effecting 1% users only"