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Old 11-04-2011, 03:41 PM   #1
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Clutch pedal rattle

My clutch pedal rattles every time I hit a bump in the road. I looked up under the dash and the pedal is mounted on a rod with the brake pedal. The clutch assembly moves a bit and this is what is causeing my rattle. Anyone ever tried to fix this noise? Any ideas on how to stop it??

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Old 08-10-2012, 10:20 PM   #2
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I have the same problem and was hoping to find a fix on here! My jeep is an 06' TJ Rubicon with 55,++ miles. I started to notice the rattle in the clutch pedal around 5,000 or so miles ago. It looks to me the the clutch pedal rod is plastic that pushes on the master cylinder and has become warn and this causes the clutch pedal to become loose and enables it to move back and forth. This movement makes it rattle when you hit bumps. I am thinking of replacing that rod but I think it will just ware again and start rattling again. Hopefully will chim in with a permanent fix.

Hugo

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Old 08-10-2012, 10:25 PM   #3
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I"ll have to look at the manual, but there should be some sort of bushing the pedal pivots on.

*EDIT*
There are two.

#2 in the diagram. Bushing, clutch and brake pedal shaft, mounting. Part # 04294639

#9 in the diagram. Bushing, hydraulic clutch actuator. Part # 04446361

I'd suspect the shaft bushing before the actuator bushing. Look underneath the dash and wiggle the pedal side to side and see if you can recreate the sound. If it does, see if the pedal looks like it's rocking on the shaft.

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Old 08-10-2012, 10:27 PM   #4
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My '02 rattles too, pretty badly when I'm out wheeling, but it isn't as noticeable on the road. I have looked at the pedal and the mounts several times, but wasn't able to come up with a solution. There is play in the pedal at rest from the front of the jeep towards the back, but the rattle seems to come from the pedal moving sideways on it's mount, so the play in the pedal doesn't appear to be the problem. I have just started to wheel with my left foot behind the clutch holding it in place; it get's really annoying on rough trails!
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Old 08-10-2012, 11:12 PM   #5
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Part numbers

Quote:
Originally Posted by s14sh3r View Post
I"ll have to look at the manual, but there should be some sort of bushing the pedal pivots on.

*EDIT*
There are two.

#2 in the diagram. Bushing, clutch and brake pedal shaft, mounting. Part # 04294639

#9 in the diagram. Bushing, hydraulic clutch actuator. Part # 04446361

I'd suspect the shaft bushing before the actuator bushing. Look underneath the dash and wiggle the pedal side to side and see if you can recreate the sound. If it does, see if the pedal looks like it's rocking on the shaft.

My pedal moves from front to back of the vehicle. For me it's Hydraulic rod actuator. Do you have the rest of the part numbers actuator rod.

Thank you,
Hugo
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Old 08-10-2012, 11:31 PM   #6
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Quote:
Originally Posted by My06rubi View Post
My pedal moves from front to back of the vehicle. For me it's Hydraulic rod actuator. Do you have the rest of the part numbers actuator rod.

Thank you,
Hugo
The catalog shows the rod is part of the clutch master cylinder assembly and doesn't have a separate part number. I even googled a little bit and didn't see it available by itself.
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Old 08-11-2012, 09:08 AM   #7
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Quote:
Originally Posted by s14sh3r View Post
The catalog shows the rod is part of the clutch master cylinder assembly and doesn't have a separate part number. I even googled a little bit and didn't see it available by itself.
S14sh3r,

Thank you. The funny thing is when I pull my clutch pedal towards me I notice the rod come with it. So there is something worng or its listed with the mater cylinder? I will have to go to the dealer parts department and see if the guy there can help me find whats up?

Thank you,

Hugo
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Old 05-20-2013, 04:05 PM   #8
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I had bushings replaced in brake pedal in my 12 rubicon. Noise was gone for bout 100 miles. Now back to same noise issue?
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Old 05-20-2013, 04:23 PM   #9
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Just had the exact same thing and I think I figured out the issue (for once)

I got underneath the dash with a flashlight (not easy!) and studied it, and saw that at the point where the clutch pedal attaches to the actuator rod. As you will see, the clutch pedal has a solid metal nub that goes into the round hole of the actuator rod. There is a little plastic bushing that slips over the nub and holds it in the hole. That is a piece of crap part and tends to break after a few years of use.

NOW here is what happens to cause the "wiggle" or play in the pedal, and what happened to mine:

Without the plastic bushing (or if the bushing breaks a little but hold together) it creates play at that connection. If not addressed right away, during the thousands of times you press the clutch pedal, the metal nub actually wears against the hole of the actuator rod, and instead of a circle, you will get something like an oval shape (again from the back and forth metal-to-metal contact over time). This allows the nub to move back and forth a slight bit even though still attached to the rod, and that is what causes the clutch pedal to wiggle or rattle over bumps. Honestly, for two years, my plastic bushing was completely broken, and I have no idea how or why my clutch pedal stayed attached to my actuator rod!

To fix mine, I got a piece of nylon tubing, some washers and a couple c-clips. I slipped a cut down piece of nylon tubing over the clutch pedal nub. This helped make up for the "oval-ness" of the clutch actuator rod hole and make a tighter fit. Now, put the nub through the hole and put one or two washers over the nub. Use the c-clips to hold it all together. Works great and saved me from buying a new actuator rod/slave cylnder unit.

NOTE: If your actuator rod hole is worn and made into an "oval" like mine was, buying a new plastic bushing from Jeep or anywhere else WILL NOT WORK. I tried. This is because the play at the connection actually crushes the new plastic bushing the first or second time you depress the clutch pedal. Once the bushing is cracked or crushed, it won't hold the connection tight enough. That bushing is designed only to go into a perfect circle.

To give proper credit for the fix I used above, I got the idea from this fine gentlemen who figured it out and posted a write-up. I don't think he had the oval problem, but the fix works just as well:

http://www.southernhighrollers.com/t.../tj_clutch.htm

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