I did this with the pedal cluster in the car and it was easy in the end. Attempt 1 was with the drivers seat in the car and the clutch master attached to to the pedal and I got the spring in. It was a absolute bitch and while I got it in it did not have the plastic bushings on the end that sit in the pedal cluster. This made it worse because the ends of the spring would bind and increase the tension instead of the assist. By the time I got that far I had already crippled myself and left it as it was so I could regroup and go at it again. I have a single mass stage 3 Clutch Masters clutch and it was a brute to operate. The spring has a lot of tension at the top of its stroke and as it goes to the floor it has much less. The clutch on the other hand had lots of tension whether it was engaged or disengaged.
On attempt 2 I removed the divers seat to get some room and then removed the master from the clutch and it took about 5 or 10 minutes. Just push the clutch pedal to the floor and then it is easy to remove the old spring and get it out of there. When you buy the S4 pedal spring you will need to buy the two bushing for the ends of the spring where it sits in the pedal cluster or bore them bigger with a drill, I drilled mine out. Make sure to look at how the old spring sits before you remove it so you can get the new one in the same position. I did this years ago so I don't remember how I did it but I am pretty sure I hooked the old spring off of the pedal by pushing it up and over the top of the pedal and put it back in the same way. When the clutch pedal is to the floor there is very little tension on it so it was not too bad hooking it back on even though the S4 spring is a lot bigger.
Is the new spring a lot lighter? No, it is not. Is it better? Yes, it is. I had to move my seat further forward to get enough leverage on it and with the spring it is a bit easier. The Clutch Master clutch does nothing until the pedal is about 3/4" - 1" from the top of its travel so when you were shifting/driving you pretty much had to dump the clutch until the top of its motion and then catch it and modulate it. With the S4 spring it gets easier to work the clutch so it did make a difference and with the slave removed it is easy to get the spring on without worrying about getting a donkey kick to the head with the clutch pedal. There is pretty much no way I could get it on with the slave attached as per attempt 1 as this is when the assist spring is under its highest tension. I did not find any issues with the clutch after the spring change and other than it feeling lighter the clutch works just the same as it did before. When the old spring was in there I stalled this car so many times because the clutch was so grabby and it was so hard to modulate but since the spring replacement I don't think I have even stalled it. BT cars with no bottom end torque and a grabby clutch which is hard to modulate is the perfect recipe for stalling an engine.
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Originally Posted by jordeeeezy
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