clutch adjustment or clutch cable problem

[jtfreels]

I am having a problem with clutch adjustment; yes I’ve searched and read a lot but still puzzled at what I’m seeing.
A short background, I replaced the clutch, clutch cable and throw out arm about 43000 miles ago. The throw out arm had broken. That was almost 6 years ago.

A few days ago, with the clutch pedal ALL the way down, and having to press more I could barely change gears.

Time to do an adjustment, I think so…

Unhooked the clutch cable.

Took off both the short and long arms at the clutch so that I could clean and lube the long arm.

I set the gap at 1.2mm and then hook up the cable to adjust to bring it down to 1.0mm.

And at that point I’m out of adjustment on the cable; the threaded portion of my clutch cable does go the whole way on the metal tube (is that normal). I have also adjusted at the clevis on the pedal end to take it in as much as possible.

I can only get about 20mm of travel when the clutch pedal is push down. After testing this a few times the 1.0mm gap at the arm is still there. (I do have that adjustment screw almost all the way in at the arm.) The omega arm is in the correct position.

Is this the cable? Do I simply need a new one? (I’ve not had the pleasure of having a bad clutch cable yet, so I’m not sure how that presents itself).

Thanks

Jay

[tobluforu]

43k on a clutch cable, I would say that you got pretty good mileage out of it.

[schumicat]

you can increase the travel by moving the clutch stop on the floorboard.

[pete3799]

Roll pin in the clutch pedal OK?

[steve911T]

Check also to make sure the part on the transmission that hold the clutch cable in place did not break off. Happened several months ago to my brother's 86 Carrera. Steve

[Hugh R]

If you have an Omega spring make sure it is flipped up against the heat exchanger. It will sit in two positions. If its not, take a screwdriver and push to the other direction up against the heat exchanger. I had that problem and took me awhile to figure it out, with help here. Sorry, I just re-read and you stated the Omega is is the correct position, double check.

[dentist90]

Hate to think it, but it may be the throw out fork again. This just happened to me. Symptoms were the occasional ca-chunk of the gears shifting, then shuddering from the clutch as it was released (fork arms were pulling unevenly). After I took up all the slack there was in the cable it was good for about 3 or 4 shifts, then couldn't engage any of the gears from neutral again. Good luck.

[rusnak]

There is additional adjustment on the clevis end of the cable. Check that.

Tip: Place a brick under the clutch pedal while re-attaching the clevis.


Edit: Ok so I see you checked the clevis adjustment? Make sure the clutch cable sleeve is seated fully in the firewall. Pull the large arm that the omega spring is attached to toward the rear of the car. There is a very small range of adjustment of the cable. Something must be installed wrong.

[jtfreels]

Thanks for the replies guys, I've covered the suggested checks, clevis, seating in the firewall, moving the adjustment point on the floor board, the omega spring (Hugh read your similar thread twice )
I don't think it is the fork as I don't lose what adjustment I have (I had to drive the car home about 15 miles, as long as I pressed through the floor board I could shift it)
I'm going with the clutch cable..... how ever I do need to fix some oil leaks in the so called triangle of death, so I'll be pulling the engine so I'll be able to check the fork, clutch etc.

Unfortunately, my mother has been in the hospital and my son is getting married this weekend, so garage time has been limited. I'll be getting my hands dirty next week.

Thanks

Jay