Why is my clutch pedal is really stiff?

Poor clutch pedal feel can often be attributed to binding of moving mechanical parts. Alternatively, problems in the clutch hydraulic system may be to blame, or a combination of both.

Despite popular opinion, it is possible to have a DSM that has a 'good' feeling clutch pedal. The key points appear to be to grease all the moving parts - throwout bearing, clutch fork and pivot ball - with a high-quality grease, and to replace the old stock clutch line with a stainless steel line (or, at least, a new rubber line). These items combine to prevent mechanical friction and hydraulic problems that can contribute to a poor clutch pedal feel.

Stronger clutches such as Centerforce Dual-Friction and ACT 2600 clutches have long had the reputation of providing a very stiff pedal. In these cases is it even more important that the clutch installation pay particular attention to the above items. In some cases, owners have reported their 'heavier' clutches feel better than 'lighter' clutches in a different car.

There have been many good reviews using Advanced Clutch Technology (ACT) Streetlite Flywheel and Southbend Clutch and Pressure Plates.

If you have the money, you can look at Twin Disc Clutch System from ACT ($1400+)