Reports have been coming in for a few years now, and in increasing numbers, that there might be a problem with the welds on the clutch pedal assembly that hold it to the firewall.
Ok, here is the real issue that needs attention:
The upper two spot welds have cracked and separated from the firewall on quite a few cars, resulting in a serious problem.
The squeak you hear is the crack forming and growing. The sound is made by the two pieces of metal sliding between each other. The popping sound that follows is the metal catching an edge, then releasing.
A spray of WD-40 will make the squeak go away, especially early on. But it is only delaying the inevitable. The weld will still tear, although, quietly. And once it has torn, the popping will come. Some more WD-40 will turn the pop into a thud, but the damage is done.
Subaru Impreza Clutch Bracket Repair | I have heard quotes from the dealership in the $2800 range to repair this problem. But you may be in luck! This issue has become so widespread, Subaru extended the warranty on affected cars by 12 months and 12,000 miles.
I encourage anyone who has this issue to confirm that they do indeed have a failed weld from the factory. If you do, I encourage you to contact your dealer or Subaru of America and ask what they are going to do for you.
If you have an aftermarket clutch, you might be out of luck... but these failed welds are showing up on non-performance oriented non-turbo models as well. Even with an aftermarket clutch, they should not be failing.
Even if Subaru agrees to assist you, you may still be left with 50% of a $2800 bill. It's worth it to have a properly functioning vehicle, but an issue you shouldn't have had to deal with in the first place.
Subaru recommends removal of the entire dash assembly, front carpet, pedals and steering for proper access to re-weld the broken welds. Most of the items removed are so they are protected from welding sparks. Here is how we tackle the issue and why it is a cost-effective best alternative:
We use stainless steel mechanical fasteners with nylon locking nuts instead of welding the broken firewall welds, therefore we don't have to remove nearly as much of the interior and reduce the repair time significantly.
O8 Subaru Impreza Repair | The fasteners spread the load over a greater area than spot welds would can be inspected and adjusted (if needed) at a later date. This leads to a better repair in less time, which is a considerable benefit (lasting value for a much lower price) for the customer.