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DIY: Do It Yourself
Post here to share or improve your wrench turning skills! All BMW E46 DIY tips, tales, and projects discussed inside. Learn to work on your car and know the right BMW parts you will need!

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Old 06-14-2013, 06:35 PM   #1
IGotTheKeys
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Join Date: Mar 2013
Location: California
Posts: 13
My Ride: 323i
DIY: Clutch Stop/Ignition Switch Solution

Here is what I did after installing my own clutch stop when my car wouldn't start due to the ignition switch plunger not being...plunged. I did this on my 2000 323i, but know this won't work for every E46 as the switches changed later on. Maybe this method can be tweaked to fit other applications.

First, parts. Rubber stopper, sheet metal screw, and washer. All can be bought at the hardware store. Sheet metal screw should have coarse threads so it won't strip easily inside the rubber stopper. Washer is optional, I had to use one for adjusting the depth of the stopper.
[IMG][/IMG]

Second, drill a hole in the plastic pedal frame. Line it up with where the plunger hits the plastic. It was awkward, but I fit a normal sized drill in that area down by the pedals. I also started with a small bit and worked my way up to correct size of the screw as to not chance cracking the plastic.
[IMG][/IMG]

Lastly, shave the rubber stopper down to the correct size (short enough so it doesn't depress the plunger fully before hitting your new clutch stop). Insert screw on one side of plastic and turn into the rubber stopper on the other. I used contact cement as a "thread locker" because I stripped the screw in the rubber.
[IMG][/IMG]

I'm thinking this will be a good permanent, removable solution as compared to gluing or taping something to either the pedal frame or plunger top. Hope this helps someone!

Last edited by IGotTheKeys; 06-14-2013 at 07:20 PM.
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