Clutch Adjustment Problems

ckmaggie · ckmaggie's Garage

Read some previous threads on the subject but I am still confused.

Performed factory adjustment per 101 Projects. I was able to get the 1.2mm clearance w cable removed. Then connect cable, tighten everything back up to get the 1.0mm required clearance. The problem is when I pushed on the pedal (heard a thunk of sorts) and went back under, I had no clearance at all. I then began backing off the clutch housing nuts, still w no clearance. Got to the point where I removed the cable again, and b/c I still had no clearance (this is strange b/c had 1.2mm clearance when cable was removed before but now it vanished) , I backed out the stop bolt to 1.2 once more. Reattached cable and tightened to 1.0mm and when I pushed the pedal (again, thunk), again clearance was gone; and backing off housing nuts seem to do nothing. At this rate, I have no more to go back w the stop nut.

I am assuming the spring on the spring arm is to blame but I am not certain. When I backe off the nuts when I lost clearance, the spring was moving.

BTW - I was not experiencing any issues w my clutch other than I thought it was grabbing a little high and at times it felt a little tight coming our of gear. No previous clutch work on 43k original miles.

Chris

Kevin Stewart · 10-29-2003, 07:34 PM

did you put the spring on then push it back to its stop? then you put the arm on its kinda hard to do, Kevin

Tim L · 10-30-2003, 04:41 AM

If the lever isn't moving freely on the shaft you will loose the gap and it won’t come back. I would remove both levers and make sure the long lever moves freely on the shaft.

Tim

JC930 · 10-30-2003, 05:55 AM

Don't forget to block the clutch pedal in the up position, before you adjust the cable. Spring has to be cammed over to it's stops also.
jc930

ckmaggie · ckmaggie's Garage

What do you mean by

"Spring has to be cammed over to it's stops also."

Kevin Stewart · 10-30-2003, 07:44 AM

you put the spring on, the you take a bar and push it back to the stop, then slide lever on get adjustment, make sure the pedal is all the way up, then connect to the lever making sure there is a washer on both sides of the cable when you tighten it, Kevin

ckmaggie · ckmaggie's Garage

Here is a picture I found:

I assume when you say spring, you are referring to the "u" spring labled in the picture. Which way does it get pushed? Should the U be closing? I never took the spring off; merely unhooked the clutch cable began to adjust the screw.

I realize this is not that difficult; I must be thick.

Chris

JC930 · 10-30-2003, 02:55 PM

With the cable off, you take a bar and pry the spring arm back towards the rear of the car I think. You may have to remove the snap ring off the clutch arm and take off the clutch arm and you will see what we mean. The spring arm will travel quite a bit and you will understand what we mean by the spring "camming over". If it doesn't move try going the other way and you will know what we mean. Make sure the pedal is up all the way.
jc930

JC930 · 10-30-2003, 03:01 PM

If you have someone to push in the pedal after you get it adjusted I think your suppose to have about 25mm travel. Check more posts on this as I checked the factory repair manual on this earlier but I'm at work right now.
jc930

Kevin Stewart · 10-30-2003, 04:14 PM

ok you have a picture, is this a 930 tranny? im not sure if they are different if its the same as a 915, put spring on you will have to push towards the front of the car, you will have to kinda hold the spring real pain, then put the spring arm on make sure the u spring stays, this is when you get the adjustment, put cable on and adjust, you may have a bad clutch arm, where are you located maybe we can find you some help, Kevin

Kevin Stewart · 10-30-2003, 04:16 PM

by the way if you havent taken the u spring off leave it alone, if there is not a washer on both side of the boss that the cable bolts to it will slip, Kevin

ckmaggie · ckmaggie's Garage

I think what Tim writes above is spot on. The spring arm is not moving freely on the lever. If I understand the operation correctly, The spring arm should move freely on the lever; in doing so it should press against the clutch arm (which is splined onto the lever) thus actuating the clutch.

I have sprayed w lubricant and will let it sit overnight.

Thanks for your help.
Chris

Kevin Stewart · 10-30-2003, 07:52 PM

no your wrong if i understand you, with the u spring against its stop, the clutch arem lever should have play, Kevin

Tim L · 10-31-2003, 06:51 AM

Yes, the spring arm should move freely on the shaft. If it's not you should remove both arms and lube them. Then you will be able to adjust the clutch with required gap.

Tim

ckmaggie · ckmaggie's Garage

I'll check it out tonight and repost.

Thanks again.
Chris