This is the end of my clutch master cylinder rod the goes up to the pedal. It's a 4th gen slave and going on a 3rd gen pedal. The problem is there is about a 1/16" difference in the I.D. of this and and the stud on the pedal which translates into about 1" of floppy pedal at the pad. Looks like there was some sort of bushing that went in there to take out the slack? Does anyone know what was probably in there orginally? And if so, what it's made out of? Cause I found a snap in nylon bushing that I can make work, but not sure how long the nylon would hold up with all the sheer load that it will see over and over again. I also have a piece of copper tubing that I think that I can make work well. But which ever I use, I wanna make sure it's a propery material that will hold up for awhile.

 

The bushing in a 4th gen m/c eyelet is a hard black plastic like deal. Problem is, when you put the original 4th gen bushing back in the eyelet, it won't fit over a stock 3rd gen pedal pin, so your best bet would probably be to fabricate one like you were saying. Also the 4th gen m/c rod is held on the pedal pin by a metal clip, just like the clip that holds the brake booster rod on the brake pedal. It's actually a much better way than that cheesy snap-on nylon bushing our 3rd gens use. Your 3rd gen pedal pin should already have a groove cut in the end of the pin for one of the metal clips. Mine did anyways. So fabricate your bushing and scrounge up a metal clip for the pin and you should be good to go.

 

Cool, well this is the setup that's I've run for the last couple years and the slop in the pedal kinda bothered me, just never did anything with it till now. Thanks for mentioning that the OEM one is a type of plactic. I'm assuming that it's nylon so I'm gonna use the snap in nylon bushing that I picked up from ace.

 

That's cool. If the nylon bushing ends up giving up too quick you can always make it even better with some sort of metal bushing at that point. On the setup I put together for my car, I bought one of the really nice McLeod adjustable clutch m/c's that's meant for 4th gens. It has a swiveling, rod-end type bushing in it. Since I didn't want to screw up that really nice bushing, I ground down the original 3rd gen pin on the pedal and drove it out with a hammer and punch. Then I dug through my organizer and found a brake booster pedal pin. Turns out it was the exact diameter needed to fit the 4th gen eyelet. Since it's smaller than the 3rd gen pin I drove a Hurst shifter bushing into the pedal hole, then pressed the pin into the shifter bushing and had a buddy tack weld it in place on the 3rd gen pedal. Now I've got the right size pin to fit the 4th gen m/c and it uses the nice metal clip to hold the rod on. Since I wasn't in a big hurry to get it all put together, it was actually kinda fun fabricating everything just right!

 

Here's a few pics of mine.