Clutch issues - 86' Carrera

[ohbugger]

Hi all,

A friend is having trouble with the clutch on his 86' Carrera. He replaced the cable and said that it worked great for a day, then started being trouble again. Today we tried replacing the helper spring, but cannot get the mechanisms adjusted right.

Based on the pic I stole and edited below, his car's #1 lever is in a position where the gap between it and the piece that the cable attaches to (at #2) is way too much; maybe a half inch, instead of the feeler-gauge sized gap there should be. If we slip #1 out and rotate it one tooth over, it is too close (won't slide back on as it hits the other piece).

There was originally no play in piece #1, but toward the end of our time in the garage it budged and now it will rotate slightly.

Hoping he's not in for a new clutch..?

[James Brown]

adjust that bolt next to #2 to the correct gap, then adjust the clutch cable to the correct setting, play in that shaft by #1 is ok, if your find your running out of adjustment, might be time for a new clutch.
use the tech article or a bentley manual to aid adjustment

[Marc Bixen]

If you adjust it then have a major change, re-adjust it and again have it go out of ajdustment quickly, you may have a cracked release fork.

[James Brown]

could be but the next adjustment will be the last, then you will know for sure!

[pete3799]

Could be the roll pin in the clutch pedal shaft has let go.

[ohbugger]

Originally Posted by James Brown

adjust that bolt next to #2 to the correct gap, then adjust the clutch cable to the correct setting, play in that shaft by #1 is ok, if your find your running out of adjustment, might be time for a new clutch.
use the tech article or a bentley manual to aid adjustment

James, ok, I believe we did these adjustments correctly, and even with the bolt next to #2 all the way "out", there was still enough space to stick a wrench in between.

Could it be the new clutch cable is too long or failed and stretched after one day? I remember seeing posts where some of the clutch cables for our cars are a bit too long.

Will get back once we talk, thanks for all the replies so far.

[gregwils]

One quick question. Did you remove the clutch cable from arm when you set the initial gap at #2? If so, then I am going to agree with Marc, the release fork may have developed a crack which has allowed it to bend. It can't be that the cable is too long for the issue you describe, since the cable should be disconnected when you set the initial gap.

The only thing #1 arm does is to pull the release fork back to release the pressure on the pressure plate when you depress the clutch. It's a lot of pressure on a part that is not that strong and failure is common, which is why Wayne includes a new release fork in his super clutch kit. It could also been the release fork pin.

IIRC, a bent arm would create too large a gap like you have. It's a pain, motor has to come out, then you start into the while I am in there. I would at least examine the clutch, PP, flywheel, release guide, crank seal, etc.

Let us know what you ultimately conclude. I have an '86 as well.

[DG624]

I am in the process of replacing many of these parts on my 86...I will be looking to see how your adjustment works. My bracket was worn and also the clutch spring and numerous parts. I had a bracket replaced but still need more fixing.

[Marc Bixen]

Good call pete3799. We've seen that a couple of times also.

[nettles503]

How did this ultimately get resolved? I'm in the middle of a clutch cable replacement and having the exact same issue. Would appreciate any help offered. Thanks.

[James Brown]

Dan, the gap between the bolt and the arm should be set with the clutch cable loose at the 2 jamb nuts, is that set correctly?

[nettles503]

James, no. I can't get the small arm positioned properly. The gap is waaaaay too big, or if I move the arm one spline, it won't clear the large arm. The cable is loose at the jamb nuts.