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Old 05-14-2014, 12:06 AM   #151
p0staldude
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Quote:
Originally Posted by Armyofcase View Post
Any of these cars have stock clutches in them?
I had a stock clutch when it started
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Old 05-28-2014, 02:47 AM   #152
Scary
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Originally Posted by Armyofcase View Post
Any of these cars have stock clutches in them?
Mine has stock clutch as well.
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Old 05-29-2014, 02:27 AM   #153
usfsfire42
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I have an 09 with 90k on it and the stock clutch and it sometimes squeaks
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Old 06-09-2014, 07:35 PM   #154
tirkish
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Sorry to raise a dead thread, but add me to the list:

2009 WRX
Stage 2
Stock Clutch
108k

Started squeaking and clicking about 2 weeks back, then last week I was having trouble shifting... did the old search-a-roo and found out I was one of the unlucky ones.

1) Dealership (outsourcing to bodyshop) quote $2400
2) SoA contacted and ball is rolling there
3) Complaint filed with NHTSA
4) My insurance co. is also investigating to check if there's any claim, for extra caution (though it's a longshot)
4) Updates to come... keep your fingers crossed!
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Old 06-20-2014, 01:54 PM   #155
Nicodomeus
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Mine is doing it also, I am going to DIY it myself and post a howto
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Old 06-24-2014, 10:25 AM   #156
tirkish
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Quote:
Originally Posted by tirkish View Post
Sorry to raise a dead thread, but add me to the list:

2009 WRX
Stage 2
Stock Clutch
108k

Started squeaking and clicking about 2 weeks back, then last week I was having trouble shifting... did the old search-a-roo and found out I was one of the unlucky ones.

1) Dealership (outsourcing to bodyshop) quote $2400
2) SoA contacted and ball is rolling there
3) Complaint filed with NHTSA
4) My insurance co. is also investigating to check if there's any claim, for extra caution (though it's a longshot)
4) Updates to come... keep your fingers crossed!

Update

SoA responded with this boilerplate nonsense:

Quote:
Hi Mr. Tirkish:
I have reviewed your case and we can offer $500 towards the repairs based on age and mileage.

So, I immediately responded with the following:


Quote:
Hi xxxxx,

I'm not sure I understand.

Does Subaru consider the firewall and clutch assembly "wear items" that require general maintenance in a 5 year old car?

My car is currently inoperable, the firewall has a breach due to a manufacturing defect and there is a potential of completely losing both clutch and brake functionality altogether.

I would imagine Subaru would step forward and resolve the issue for me, as it has done on many other 08-11 Imprezas with the exact same issue and with various ages and mileages all over the US. A manufacturer with such a high regard for vehicle safety selling a vehicle with this kind of defect is just shocking to me.

I'm trying to avoid the hassle and heartache of joining one of several class action lawsuits being filed by Subaru owners over this very issue. ( http://www.subarufirewallclassaction.com/ ). This is my second Subaru (my first I drove daily for 9 years), and my family's fourth (my brother bought the first Hybrid CrossTrek sold in Maine a few months ago). This has really put a tarnish on our brand loyalty.

That said, I also find the quote that my dealer's bodyshop submitted is astoundingly high. The repair requires the removal of the dash (1 hour of labor) and a small amount of welding. I've also already spent $200 on a rental car for this week while waiting to get this resolved.

I would like to find some kind of solidarity with SoA on this.
It worked.

I sat for 3 days, received a phone call from my SoA contact and was told that they decided to cover the whole enchilada... they negotiated with the dealer's body shop, and got the final bill down to $2100.

I paid nothing.

SoA also stepped up and paid for 5 days car rental, as the dealership did not have a loaner car.

Moral of the story: be cordial, but firm. SoA knows this is an issue and that they are responsible. Feel free to use my letter if it helps you.
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Old 06-28-2014, 11:29 AM   #157
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Wanted to add my case. 2009 WRX with 60000 kilometers. As far as I know it's the stock clutch (second owner of the car). Started having the problem at about 45000 (that's probably when the first weld broke). It only got worse over time. Took off the windshield wiper cowling and seen the broken welds. Even with video of the broken weld spots the dealership was still skeptical. They wanted me to bring it back to them a week later when a subaru canada rep was going to be there. I didn't want to take any chances so I stripped the dash before I brought it back. I was able to show them the broken welds without any doubt. They agreed to fix in good faith but wouldn't put back on my dash lol. I was okay with that.

Got the car back after a week and a day later the clutch pedal feel is even worse. Brutal squeak and crunch feeling from it when coming off the pedal to let it re-engage. It was so bad that I even took off the windshield wiper cowling again because I thought I had rebroken the welds. That was not the case. The welding job was very good and it is absolutely rock solid near the top of the bracket. However, this has now exposed another problem. The firewall around the master clutch cylinder is terribly thin. Every time I depress the clutch pedal the clutch cylinder travels about a 1/2 inch, bending/warping the firewall. It gives a terrible feeling in the clutch pedal. Again much worse than before.

I thought about putting in a grimspeed master cylinder brace in but that's for the brake cylinder. The way the firewall bends when the clutch is depressed actually pulls the brake cylinder inwards, towards the driver, as it pushes the clutch cylinder outwards. The cylinder brace wouldn't do anything to help this unless you welded it to the master cylinder lol.

I saw that armyofcase on these forums has set up some sort of brace that connects his pedal assembly to the internal structure of his dash. The next chance I get for some time to work on the car I'm going to pull the dash again and see about fabricating something similar.

Really disheartening that I would have to go through this kind of trouble myself to fix an issue that is really a design flaw in the car.
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Old 07-09-2014, 10:09 PM   #158
Scary
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So, click started to come back, what a pain. I attempted to do what I'd done before... the first time I got lucky. Read below.

Quote:
Originally Posted by fatrabbit View Post
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.
This happened to me... and it scared the **** out of me. It started with a little vapor, then got really smokey. I ran and got the water hose, sprayed the outside for about 30 seconds, then it got much worse. I ended up spraying a bit up under my dash before it went out. DO NOT WELD FROM THE OUTSIDE!

I pulled my dash out today, took about 3 hours to get out. Immediately, I saw the insulation had charred under the dash.

As far as the clutch, I sank 6 1/4" self-tapping screws, built a brace out of 2 pieces of 6" long 1/8" strips of sheet metal, ran a bead along the trouble area, then welded a 1/2" tube of DOM to the steel dash tube frame just above the fuse box. This took about 6 hours, it is strong, and the click is long gone, though, the clutch pedal started squeaking. I lubed all the pivot points with tri-flow, and now it is quiet and not so damn firm.

If I had it to do again, I would have went to my local Subaru and contacted SOA to have this fixed on their dime. However, I like tinkering, so it really wasn't horrible until I had the mental realization "I have to put this all back together now."

It took about and hour and a half to get the dash back together. The glovebox light wire went missing... However, I'm not pulling it all back apart to find that damn wire.

tl;dr - Don't weld from the outside, just be politely persistent with SOA and have them fix the blasted thing.
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Old 08-27-2014, 12:33 PM   #159
OMS1
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I just read this whole thread and I'm concerned I have the same problem but I have a 2013 WRX. Can this firewall issue affect my model year? When I depress my clutch there is a creaking noise and then when I let up on the clutch there is a clicking noise. I've brought it in to the dealership twice and both times they said they could barely hear anything and what they did hear was normal. I can post a video later with the noises to see what you guys think.
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Old 09-06-2014, 03:58 PM   #160
fsjay723
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Default Firewall Weld Issue - affects all 08 to 14 WRX

I have a 2011 WRX (no engine or clutch mods) and have the same issue.

My clutch is slipping and needs replacement after only 47k and when I took it to Subaru dealership 2 weeks ago to look at all they said was that the clutch was slipping. I then took it to a Subaru tuning shop to replace my clutch (Precision Tuning, NJ) and they said it had the firewall issue. All they had to look at was the firewall flexing while looking under the hood.

I called SOA to open an incident and they said I had to take it to the dealership to get it reviewed and then they would contact the dealership.

I am betting they will attempt to either charge me to have them review it which I am not paying. So annoying.

I am not fixing this myself so I will complain to everyone and anyone until I get this resolved...

to be continued.

This issue affect all WRX from 08 - 14, plus I heard a few people with a 2015 that might have the same issue. If you are thinking of getting a 08-14, don't unless you get a STI because the transmission is different and does not cause the problem even though the welds are the same.
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Old 09-14-2014, 01:08 AM   #161
esp1818
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After more searching about this problem I think this is the best way to fix it: PSA: The dreaded clutch clicks, squeaks and pops. Along with welding or bolting the broken welds underneath the wiper cowl.
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Old 10-06-2014, 12:35 PM   #162
tcho
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So there are about 5-6 spot welds holding the inside firewall (which your pedal assembly is also attached to) that broke in my car. I tried to tough out that annoying squeak noise but it got worse and worse. Pretty much all the welds broke and it was getting harder and hard to shift into any gears and eventually I couldnt shift any more without grinding the F@#K outta my gears. Then I couldnt engage my gears at all. So I said screw it and took out the dash and cover to my windshield wiper motors and drilled out the welds and put bolts and locking nuts in. Its all fairly easy to do. In fact I might have been able to do it with out removing the dash. Im 40k miles into my own fix with out any shifting issues or squeaks. My cluch isnt hard either and is pressed down effortlessly. I spent a total of $100 (corded drill, drill bits, and 8 bolts w/nuts and washers which I only used 5 to fix) and about 3 hours of labor.. saved $600 doing it myself and recommend doing it yourself before you cant shift anymore. SOA are playing hard to get and are only giving very few people the option to re weld the broken welds which end up breaking again 15k miles down the road.
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Old 10-12-2014, 07:55 PM   #163
Hammertime
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Hey guys first time poster long time reader I have a 08 wrx clutch pedal squeaks getting worse pulled wiper cowl off and spot welds are not broken but the break pedal moves when I push the clutch down any suggestions I also checked the transmission not there and lubed up the whole clutch pedal assembly trying to get the squeak to stop
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Old 11-12-2014, 08:35 AM   #164
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More details on the diy bolt and washer fix? What size bolts, washers, etc. Is it obvious what needs to be drilled?
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Old 11-12-2014, 10:36 AM   #165
tcho
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Quote:
Originally Posted by Hammertime View Post
Hey guys first time poster long time reader I have a 08 wrx clutch pedal squeaks getting worse pulled wiper cowl off and spot welds are not broken but the break pedal moves when I push the clutch down any suggestions I also checked the transmission not there and lubed up the whole clutch pedal assembly trying to get the squeak to stop
I would take out the wiper motors as well to get a more detailed look. Some of the spot welds are a little hard to find so if your squeaking as you depress the clutch theres a 90% chance its the fire wall welds broken some where.
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Old 11-12-2014, 10:41 AM   #166
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Quote:
Originally Posted by big_cg View Post
More details on the diy bolt and washer fix? What size bolts, washers, etc. Is it obvious what needs to be drilled?
I used galvanized m12 bolts with a length of about 3 inches. I put a washer on both sides of the firewall and used locking nuts and torqued them on pretty tight. I used a 3/16 drill bit but recommend getting a step bit instead. If not make sure you have your depth rod set on your drill so when you drill thru the fire wall you dont accidentally smack your windshield with the drill and crack it bad (speaking from experience).
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Old 11-12-2014, 10:50 AM   #167
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Its also pretty obvious on where to drill. Every little hole you see under the wiper motor is a broken weld. Get some one to press on the clutch and you can see the inner part of the hole separate. The inner part of the hole is the cabin side firewall the outer hole is the engine bay firewall. They used spot welding methods to fuse the 2 together and by the looks of it the engine side fire wall was the weak side (very thin weak metal) causing it to just break at the spot welds from pressure of depressing the pedals.
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Old 11-12-2014, 11:33 AM   #168
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Gotcha. Gonna try this this weekend. I looked in the cowl this am and saw one spot weld that was broken, and one that was intact. Im getting the squeaking, stiff pedal, and brake pedal shifting when clutch is pressed.

Plan is to pull the cowl and wiper motor, drill out all visibly damaged spot welds, install 2.25" grade 8, 1/4" bolts and hardened flat washers. Ill use red threadlock and a secondary nut to keep it in place.

Might even put some silicone on the outside of the nut to keep water out, after its tightened up of course.
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Old 11-12-2014, 11:37 PM   #169
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^^^ Take some pictures would ya!!!
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Old 11-14-2014, 03:00 PM   #170
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Since this is such a blatant design error, I'm gonna try to have Subaru take care of this before attempting repair myself. I emailed SOA and informed them of the issue. They told me to take it in to a dealer to verify the condition. Appointment is next Friday.

This is the result of improper materials and joining technique for the load that the firewall takes with braking and clutch force. Of course its gonna wear down over time and flex and pop the two spot welds. D- for the Subaru engineers who designed it.
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Old 11-21-2014, 07:49 PM   #171
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Just got back from the dealer and they verified the condition. I forwarded the notes to the SoA contact. There were three other WRX's in there with the same condition.

Hoping that SoA steps up and takes care of this. If my clutch has been worn because of this also, hoping they have a new one installed.

I had a scare today also due to this. I was coasting to a stop sign and had the clutch in, and pressed the brake pedal but I couldnt push it down because the pedal had shifted over my left foot. Fortunately I realized it in time...but I definitely see how if someone was in a panic braking situation and their left foot was in the wrong place, it would result in no braking.

To those that are contemplating a DIY fix first- don't. Take your car in and contact SoA. The more who report this, the more likely they are to issue a much needed recall. Plus why waste your time fixing Subaru's crappy design?

The technician that I spoke to said he called techline and they are aware of the problem.
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Old 12-09-2014, 12:08 PM   #172
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Very useful advice here but wanted to bring up a potentially different issue?

I have a 2005 STI and my clutch squeaks horrendously. I have been loosely informed that the problem facing 2008+ guys with the firewall and weak tack welds is not the same issue that I am having.

I have actually been told that my pedal box assembly has a broken bracket and that it needs to be replaced or the existing one needs to be re-welded and re-fortified. The dealership seemed aware of this issue for the GDB chassis and quoted me $1200 for the job, which included removing the entire dashboard and steering column, towing it to a fab shop, having the existing pedal box re-welded, and everything put back together.

A local mechanic who does tuning, fabrication, and repairs on the side quoted me the same job for $700.

The car currently has an Exedy Twin and I can still drive the car everyday, just hard to find the friction point as it is never consistent.

Is anyone else aware of this issue for the GDB Chassis WRX/STIs? Is it the same firewall weld issue that the 08+s are plagued with? Can this issue be resolved without removing the whole damn dashboard?

Thanks! I am getting desperate!
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Old 12-10-2014, 08:33 PM   #173
tirkish
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Quote:
Originally Posted by Oojin View Post
Very useful advice here but wanted to bring up a potentially different issue?

I have a 2005 STI and my clutch squeaks horrendously....

You have the same issue...firewall weld failure.

Starts with epic pedal squeak, ends with your entire clutch/brake pedal assembly falling off.

Dealer. Make a stink. Contact SoA. Get it fixed.
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Old 01-15-2015, 11:52 PM   #174
cspr
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I have same problem. I contacted SoA and they are reviewing my case. In the mean time I had my shop FastAutoWorks confirm it was firewall crack/ broken but per request of SoA they had me send it to a dealer. Now dealer wants to take dash out and I haven't heard whether SoA is covering yet. Still in works. As soon as I hear something I will post my findings and results of what happens. I thank all those who have posted and added this thread. Has helped so far as pleading my case to this unfortunate situation that we all seem to have
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Old 01-15-2015, 11:56 PM   #175
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Quote:
Originally Posted by cspr View Post
I have same problem. I contacted SoA and they are reviewing my case. In the mean time I had my shop FastAutoWorks confirm it was firewall crack/ broken but per request of SoA they had me send it to a dealer. Now dealer wants to take dash out and I haven't heard whether SoA is covering yet. Still in works. As soon as I hear something I will post my findings and results of what happens. I thank all those who have posted and added this thread. Has helped so far as pleading my case to this unfortunate situation that we all seem to have


So i received a phone call from SoA Today and they said they have some good news. It was to late for me to call them back since they are closed but i will give a update of what will be done for vehicle. As to what Subaru dealer found was that 3 weld points were all broken and pulled away from firewall. hence why so much pedal movement and tuff to drive. i will post results of what they tomorrow.
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