[jcain]

My clutch was slipping at 120,000 miles so I decided to replace the disc and pressure plate.

Prior to replacing the disc and pressure plate I could depress the clutch pedal almost to the floor before engagement.

Anyway, after replacement of the disc and pressure plate and before re-installing the clutch slave cylinder I noticed that there is about an 1 1/2 inches of free travel before there is any resistance. I am sure that is the point where the throwout bearing is actually starting to press against the pressure plate fingers. At that point it takes considerable force to move the arm any further. The arm will only move another inch or so as the clutch diaphragm is depressed.

Here is the problem.

When re-installing the slave cylinder and with the slave cylinder actuator rod at it's full length it just barely contacts the arm of the clutch release shaft. I am afraid if I depress the clutch pedal at this point that it will overextend the actuator rod and destroy the clutch slave cylinder.

I looked at the clutch fork and nothing is bent. I measured the replacement throwout bearing against the original and they have the same dimensions. I also made sure that the throwout bearing was properly placed in the fork.

It seems that this would only leave the possibility that the angle of the fork and that of the arm on the clutch release shaft is no longer correct. I examined the hex bolt that holds the fork on the clutch release shaft and it is intact. I also looked at the arm on the clutch release shaft and it appears that everything is correct with it.

So here are the questions.

Should there be any free play before the throwout bearing begins to press against the pressure plate?

With the clutch pedal at the top of its travel how far should the arm on clutch release shaft be from the bracket that holds the clutch slave cylinder?

With the clutch pedal at the top of its travel should the pressure plate be applying pressure though the arm on the clutch release shaft to the clutch slave cylinder to ensure that the clutch pedal returns to its topmost position?

Is it possible for the angle arm on the clutch release shaft to change with relation to the clutch fork?

Thanks,

Jack