[Taxi!]

Originally Posted by Mr Project

Thanks guys. I do understand that, my problem was that I didn't have enough adjustment available at the pedal stop to allow for 25mm of travel.

So last night, I took wolds advice and tightened up the clevis side of the cable and then re-adjusted at the transmission bracket. As I expected, once I had the 1.0mm cable tension set correctly again, the total travel was the same 22.x mm.

I went through the plastic ABS floorboard carefully, and compared it to the remnants of my original plywood floorboard. I was hoping that perhaps the holes in the ABS floorboard were not allowing as much clutch stop adjustment as the original pieces. Not so...the ABS piece is well-made and a very good match for original.

However, it was the only thing I could think of to allow for more travel, so I expanded the clutch stop mounting holes in the ABS floorboard slightly to allow for more adjustment of the stop.

After some monkeying around with this, I got to 24.5mm of travel. I called this close enough and put the car on the ground to road test it.

That's when things went sideways. I could not get the car in gear at idle. It was clearly not disengaging the clutch. I could shut the car off, put it in gear, depress the clutch, and start it, but it was clearly still dragging the clutch slightly. After experimenting gently, the car started making horrible noises (scraping, grinding, rotational noises).

I'm fairly certain that my real problem is inside the bell housing. My pressure plate/throwout bearing is highly suspect. Sigh. Out comes the drivetrain!

I'm not sure what's causing the noises you're experiencing, but I had the same problem with my clutch adjustment recently and eventually attributed it to the aftermarket floorboards (and clutch pedal stop) that I changed with the clutch cable and springs. It just didn't seat the same as the OEM part.