tl;dr -
I replaced the clutch cable, floorboards, pedal stops, and rebuilt the pedal cluster, but cannot get 25mm of clutch cable travel. I'm 'peaking out' at a little over 22mm.
A little background for the problem: The car is my '82 911 SC. It has a 3.2l Motronic engine but the original SC 915 gearbox.
I rebuilt the engine a year or two ago and adjusted the clutch linkage when re-installing everything. The disc, flywheel, pressure plate, etc all looked fine and worked fine. The 1-2 shift has never been great on this car, but it was disengaging properly and working fine overall.
I did not have a helper available, so I didn't verify the total cable travel. I did the 1.2mm/1.0mm adjustment and since it worked I didn't check the travel
Early this year, I pulled the car out on a couple of unseasonably warm winter days and drove it - it started out fine but after 100 miles or so, I was having tremendous difficulty shifting. It was clear that the clutch was not fully disengaging. If I force the clutch pedal down as far as i could, it got a little better - enough to limp it home.
I re-adjusted the clutch linkages and drove it around the block. Problem solved! It shifted fine again. However, after running errands around town for 15-20 miles, as I pulled into the driveway I felt something 'shift' in the clutch pedal/linkage and it was not fully disengaging again.
At this point I visually inspected everything and it looked OK, but the clutch cable was obviously worn and I thought it made sense to just replace it. So I replaced the clutch cable and the little attachment parts at the pedal cluster end. After doing so, I could not get 25mm of cable travel, no matter what I did with the adjustments.
Thinking that it might be pedal cluster related, I rebuilt it with bronze bushings. Everything actually looked basically fine, but I did it anyway, and reassembled everything. I'm still stuck with a max of a little over 22mm of travel.
I'm stumped. Help!
New ABS floorboard and clutch pedal stop
Clutch pedal stop adjusted to max travel
Rebuilt cluster with new bushings and new clutch pivot pin/attachment. All nice and tight.
New cable and 1.2mm/1.0mm adjustment completed
Zero the measurement at 'rest'
Max travel with clutch pedal against stop