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Old 06-06-2013, 08:52 PM   #126
yudangorgor
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^shoot.. that's insane... luckily you are getting it fixed.

anyway here's a video of mine.. i don't think my welds are broke then tho.. at least not to the extent as the poster above.

https://www.youtube.com/watch?v=wa9bbfsR72g
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Old 06-06-2013, 11:50 PM   #127
stl2009wrx
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It doesn't look as though it is that bad. Get down and push the clutch pedal in with your hand, and if you see the brake pedal move as well, then you are having real problems. Also have someone push the clutch in and out while you check to see if the clutch master cylinder flexes in and out. That's another sign of the problem. You can also remove your wiper cowl, and see if the spit welds have separated from the firewall. If any of them have, then they need to be fixed. All these checks are very easy to do, and they will tell you if you're having the problems or not.
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Old 06-07-2013, 08:57 AM   #128
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if I have a grimmspeed master cylinder brace.. would it still flex??
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Old 06-07-2013, 05:50 PM   #129
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Yes. The master cylinder brace is only for the brake master. The problem is the firewall itself flexes, and those kind of braces rely on the firewall supporting it. Where that particular brace bolts up, the A pillar helps strengthen the firewall at that point, but the clutch master is further toward the middle of the firewall, and this doesn't have as much support from anything else. The gauge size metal Subaru uses is just too thin. This is the cause of the flexing.
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Old 02-15-2014, 07:48 PM   #130
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So, I was having the same problem as most people described here. My clutch started to squeak about 3 months ago... annoying as hell, however, not loud enough that it couldn't be drowned out by music. Over the course of that time, the noise became much more audible. Two weeks ago, I was playing with my new AP (launch control) and afterwards I noticed the squeak had become a pop, like a soda can when you straighten a dent in the side. The noise was only there when I pushed in the clutch, not out. After numerous times of trying to find the noise, I gave up and started reading last night. That search ended with this thread. This morning I pulled into the garage, and pulled apart the cowls, wipers and wiper motor. Sure enough, there was 4 spots that spot welds had broken. This is where I decided to stray from the rest of this board's resolutions.

I decided that I could see enough of the bracket underneath to fix the welds. I prepped the area by sanding down to metal all around the spots, then I broke out a 1/4 inch drill and sunk the bit roughly 1/8 of an inch (through the firewall at the points of separation) to reveal both the firewall sheet metal and what it's welded to.

After that, I used a wire feed 110 welder, and starting from the inside out I stitch welded in a spiral motion outwards. I then filled those stitches outside in. For each failed spot weld I did this (4 in all), used the flap wheel to clean up the slag. At that point, I took 2 pieces of 1/16 (sheet metal about 2.5" X 1.5") and laid them over the freshly welded sections to distribute the force over a greater surface area and welded that along the edge. I then used self-tapping screws and drove them a diameter offset from the welded sections on both sides (4 screws each piece). In all, this took me about 2.5 hours to accomplish, and it is holding very strong.

No more noise and the clutch is no longer comparable to a leg press machine.

I wish I would have taken pictures, but I didn't because I never think to until afterwards. Time will only tell how long this will last.
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Old 02-16-2014, 11:04 AM   #131
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Quote:
Originally Posted by Scary View Post
So, I was having the same problem as most people described here. My clutch started to squeak about 3 months ago... annoying as hell, however, not loud enough that it couldn't be drowned out by music. Over the course of that time, the noise became much more audible. Two weeks ago, I was playing with my new AP (launch control) and afterwards I noticed the squeak had become a pop, like a soda can when you straighten a dent in the side. The noise was only there when I pushed in the clutch, not out. After numerous times of trying to find the noise, I gave up and started reading last night. That search ended with this thread. This morning I pulled into the garage, and pulled apart the cowls, wipers and wiper motor. Sure enough, there was 4 spots that spot welds had broken. This is where I decided to stray from the rest of this board's resolutions. I decided that I could see enough of the bracket underneath to fix the welds. I prepped the area by sanding down to metal all around the spots, then I broke out a 1/4 inch drill and sunk the bit roughly 1/8 of an inch (through the firewall at the points of separation) to reveal both the firewall sheet metal and what it's welded to. After that, I used a wire feed 110 welder, and starting from the inside out I stitch welded in a spiral motion outwards. I then filled those stitches outside in. For each failed spot weld I did this (4 in all), used the flap wheel to clean up the slag. At that point, I took 2 pieces of 1/16 (sheet metal about 2.5" X 1.5") and laid them over the freshly welded sections to distribute the force over a greater surface area and welded that along the edge. I then used self-tapping screws and drove them a diameter offset from the welded sections on both sides (4 screws each piece). In all, this took me about 2.5 hours to accomplish, and it is holding very strong. No more noise and the clutch is no longer comparable to a leg press machine. I wish I would have taken pictures, but I didn't because I never think to until afterwards. Time will only tell how long this will last.
So this was all done from outside the car? No need to remove the dash? I'm having a hard time picturing the sheet metal part. Can u explain a bit more. Or if possible one day snap a pic from under the wiper cowl. Thanks
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Old 02-17-2014, 03:03 AM   #132
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My 2011 WRX does it too, I just turn the music up
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Old 02-21-2014, 10:17 AM   #133
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My car has the firewall issue on my 08, and I really DO NOT want to pay $1000+ for an issue with Subaru's engineering and short cuts. I have basic bolt ons like turbo, intercooler, injectors, etc. Do you think Subaru or the SOA will do anything about it since I have 91k miles and no warranty?
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Old 02-21-2014, 11:33 AM   #134
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Quote:
Originally Posted by dcdirtrider View Post
My car has the firewall issue on my 08, and I really DO NOT want to pay $1000+ for an issue with Subaru's engineering and short cuts. I have basic bolt ons like turbo, intercooler, injectors, etc. Do you think Subaru or the SOA will do anything about it since I have 91k miles and no warranty?
No warranty I'd say no but always worth a try especially if subaru has done all the servicing in which can play a big roll.

Could be just the clutch fork needing to be greased up plus I would consider a grimmspeed clutch brace.
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Old 02-21-2014, 12:05 PM   #135
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Quote:
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plus I would consider a grimmspeed clutch brace.
You mean master cyl brace.
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Old 02-21-2014, 01:56 PM   #136
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Quote:
Originally Posted by AcquaCow View Post
You mean master cyl brace.
They also make one for the clutch and master cylinder.
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Old 02-21-2014, 03:14 PM   #137
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Yup. Just pulled in my '09 WRX in and its making the same noise. I shined a flashlight through the cowl and saw the 2 spot welds where they are broken from the fire wall.

Now I'm curious about scary's fix. Did you weld it from the outside? Because it looks like it can be done from the outside...
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Old 02-21-2014, 04:35 PM   #138
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Quote:
Originally Posted by Subiezilla View Post
So this was all done from outside the car? No need to remove the dash? I'm having a hard time picturing the sheet metal part. Can u explain a bit more. Or if possible one day snap a pic from under the wiper cowl. Thanks
Just wanted to let you know that I just welded all the spot welds from the outside of the vehicle. I wouldnt recommend it. I was doing one spot at a time, and on the last one to the far left, the jute on the inside of the vehicle started smoldering. Took me a while to get the pieces of jute that were smoldering out of the vehicle.

But the pedal is better. But this is NOT a fix. It doesnt feel like it will last a long time.

I'm going to remove the dash and see what can be done from the inside.
This is my only DD and I dont feel like waiting for the dealer to fix my car. Thats why I did what I did. Plus, I've been in automotive for 10 years. This is not a big deal for me.
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Old 02-21-2014, 04:43 PM   #139
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my buddy had this happen to his 08 about a year ago
SOA was really cool about it
he is stage 2 and it was at like 80k miles so it was out of warranty
they covered it 100%, he even got a brand new clutch out of it and all new pedals (which was nice for him cause he was due for a new clutch soon)

the only thing is it took like a 1.5-2 weeks
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Old 02-21-2014, 07:45 PM   #140
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Mine 06' squeaked as well. I had other issues going on and ended up with a brand new transmission. The squeak was gone with the new transmission but the service tech said he went through and lubed up all of the moving parts. Try that?
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Old 02-22-2014, 02:05 AM   #141
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Quote:
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I was doing one spot at a time, and on the last one to the far left, the jute on the inside of the vehicle started smoldering. Took me a while to get the pieces of jute that were smoldering out of the vehicle.
I was actually concerned about this as well, so I threw down a sheet of thick canvas (quite heat/flame resistant). I am guessing you burnt through quite a bit on that far left one? This was my logic in drilling through creating concentric holes (both with a larger radius). I also used a 1/2" circular punch to significantly reduce the gap between the firewall and the bracing behind, basically suck them up to each other... and I was still somewhat worried about burn through. It could just be that I got lucky or mine wasn't nearly as badly separated. In any case, I'm glad everything turned out okay in the end for ya.
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Old 02-22-2014, 02:29 AM   #142
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So this was all done from outside the car? No need to remove the dash? I'm having a hard time picturing the sheet metal part. Can u explain a bit more. Or if possible one day snap a pic from under the wiper cowl. Thanks
Well... considering fatrabbit's troubles, I would say to try at your own risk. I can say this, I have a lot of experience with welding, and this is some extremely thin sheet metal, so beware.

That being said, I think this is a viable fix if you do a lot of prep work and get a good visualization of how to get the two pieces to mate together. I also think you could do this with bolts straight through, using drilled out 1/8" thick strips of 1/5"x2" sheet metal strips as washers.

What it came down to for me was:
I didn't have the time to pull the entire dash apart, and I will always choose my welding over nuts and bolts. If you are not 100% comfortable with this, have the time to pull the dash, or if you get under the cowl and realize that there is too large of a gap between the firewall and bracket, then I would choose other.

My quantum professor at school says he likes to be lazy-smart. If you have the experience to decide you can pull it off, it will save you some hours, a large headache, broken plastic tabs, and possibly a lot of money. However, if you think there's a good chance something could go wonky, just pull the dash or drill and use nuts/bolts. Better safe than sorry.

P.S. I would also like to say, it is a VERY good idea to have a friend around. My buddy had a spray bottle of water just in case I burnt through and got slag in the cabin (technically, it was Febreze, because if he had to put out a fire, I wanted it to smell fresh like a springtime meadow afterwards).
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Old 02-24-2014, 11:29 AM   #143
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Yeah, It held, but I had burnt jute smell all through the car. Just like scary said, the one on the far left was the one that gave me trouble. I did have a friend on the inside with a water bottle and I had one as well. I knew the one on the left was going to give me trouble because it was so far from the firewall.

I had him pull the pedal up and pull to the right and it still didn't reach. I slowly tacked one spot, waited, tacked the opposite side of the hole, and did this a few times.

I waited for it to cool (15 minutes each time) started from the center in a circular motion and filled it all in. Then I noticed the smoke rising from between the windshield and the dash. **** sucked.

I have pictures of what I did.





I didnt take a picture of the holes before hand. didnt think to. I figured theres enough pictures of them circulating all the subaru threads. I used a sheet metal hole cutter kit to cut out the rusted part of the hole. If you look closely, you can see the cracks that are leading away from the hole, that are rusted.



All of them were cracked, so I prepped all of them for welding.





I had to go back on the far left one because it wasnt completely sealed.



after re weld.

I didnt feel comfortable knowing that I had patched my car. I wanted to do it right. Then I started piecing everything together thats going on in my life. I just built a new house. Ill need brakes and suspension work on my car. I was going to need $600 in tires. The headlights were oxidizing from the inside of the lens. the whole interior squeaked, rattled and popped. The drivers seat had back and forward play. So it made a slight clunk when accelerating or stopping. all Bushings were shot.

so much more to list, I just gave up on it and sold it. got 16K for it. left all mods and everything on it. I just wanted to wash my hands of it. I was really bummed out about it. but I think i saved myself from headaches and heartaches when the rest of the firewall starts to rust out....

Now im waiting to see what the 2015s look like in person. If theyre too ugly, I might consider getting an amazing deal on a 2014 thats left on the lot after the new ones come out. But its the same body roughly. I might consider looking at something else entirely.....damn

at the moment, im driving my gf's mom's 2012 wrx, and the pedal is so much softer. Im thinking that the fix they had for the firewall was a much softer spring. you guys might want to look into that after whatever method you guys use for a fix. just a thought.

Last edited by fatrabbit; 02-24-2014 at 12:22 PM.
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Old 02-24-2014, 01:40 PM   #144
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Quote:
Originally Posted by trev762 View Post
They also make one for the clutch and master cylinder.
I've been looking on their site/google and can't find it, can you link me?

Thanks,

-- Dave
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Old 02-24-2014, 07:33 PM   #145
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Clutch cyclinder doesnt work. Re-welding doesnt work. Done this twice in a little less than 2 years. First time SOA paid and were cool. Second time I did it, held 2 months longer and I didnt have to wait 2 weeks for them to weld. I am too lazy to keep doing this. Trying to get a legit trade in on my car. Only thing i think they can help me with.
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Old 02-24-2014, 08:37 PM   #146
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Clutch cyclinder doesnt work. Re-welding doesnt work. Done this twice in a little less than 2 years. First time SOA paid and were cool. Second time I did it, held 2 months longer and I didnt have to wait 2 weeks for them to weld. I am too lazy to keep doing this. Trying to get a legit trade in on my car. Only thing i think they can help me with.
There is a write up to fix this with rivets and bolts. I wouldn't waste my time re welding.
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Old 05-05-2014, 11:58 AM   #147
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I decided to fix it on my 08. It's really not that bad, it took me an afternoon. The hardest part is removing the dash, there is a lot of hidden screws.

I welded the top of the bracket to the firewall and put some primer on it so that it doesnt rust:



Be extra careful, the metal is very thin. It's easy to blow a hole in the firewall when welding.

I also fixed the outside weld but did not take a picture after welding:



After 2 years, the clicking sound is finally gone

Last edited by p0staldude; 05-05-2014 at 12:18 PM.
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Old 05-05-2014, 12:42 PM   #148
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Originally Posted by Andrewxxcarlson View Post
There is a write up to fix this with rivets and bolts. I wouldn't waste my time re welding.
Yeah, I would assume drilling it out and putting bolts with large washers, or a big backing plate on it would be superior to re-welding... unless you welded in a large backing plate... then welded it to the clutch support...
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Old 05-05-2014, 11:02 PM   #149
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Any of these cars have stock clutches in them?
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Old 05-13-2014, 09:01 PM   #150
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Any of these cars have stock clutches in them?
Sorry guys/gals.. this is my first post.

I am currently going through the same issues. '08 WRX sedan, 75k miles. To the best of my knowledge, I have a bone stock clutch.
I bought the car used back in September 2013 and it had a tight clutch back then. My first Subaru and I thought that was just how WRX's were.
Noise started to happen about 5 weeks ago. I verified broken firewall welds.

To date, I have taken to the dealership, they have verified weld issues, and quoted me $1900 to repair these and to replace clutch. Though it's out of warranty, I have contacted SOA and they have been really nice about it. There is some concession that they are willing to make. However it is not 100% and only on the firewall, not the clutch.

A local shop "PRE" quoted me a higher price than the dealer, but it included the grimmspeed brace after repairs.

I suggest giving SOA a call... have a great attitude...don't go into the conversations expecting or demanding them to do anything.
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