Grinding Gears: It's the Clutch, Supid.

douglas robbins · 02-10-2003, 11:18 AM

Grinding Gears. So my gears were grinding like crazy. First and reverse were the worst, but when it warmed up even second made noise. And all the gears were hard to get into.

Pedal Stop.So I read the owners manual (not the workshop manual), and it talks about adjusting the rubber stop on the clutch pedal. So I move the stop back and now the pedal swings way back but the grinding is much better. But then it gets warmed up and its the same old grind. And its not just a little clunking but bad bad grinding.

Thinking. So then I think about it and I figure if the pedal stop helped a little then the problem must be that the clutch is not disengaging all the way. I used to adjust my Bus' clutch all the time and it was really easy.

Last Weekend. So last weekend I go to adust the clutch and find that its already adjusted all the way in and won't go any more. So I check the cable where it meets the pedal but there's no adjustment nut there. So I start to think that either the clutch is really screwed up or the PO installed a too-long cable.

Cable is too Long. I figure the cable is too long. I notice that at the end of the cable where the threaded metal bit meets the clutch arm is only partially threaded. I figure if I can just thread the rest of the metal end, that should give me the extra adustment area I need to tighten up the clutch. So I buy a tap and die kit from Sears and the 7mm 1.00 die cuts a nice thread. I extend the thread on the end of the cable by about an inch and then I cut off about an inch of the cable at the end with the Dremmel (because if you do not cut off the end, and try to adjust it out, it runs into a little stopper extending off the side of the tranny).

Readjust the Pedal. Then I readjust the pedal so that the stopper stops the pedal at some reasonable distance (lets me move my seat back a little too, and now I can see the Tach better). And I readjust the clutch. I lock the cable with double 11mm nuts. No more grinding. It even goes into gear more easily.

Result. Now the clutch does not begin to engage until about 1 or 2 inches or more as the pedal swings back from the rubber stop and it appears to lock and engage a full 2 or 3 inches or more before it comes to a rest. That said, I do not feel any "free play."

Question. Does anyone have any reason to believe my newly shortened cable is somehow presenting a false solution by masking some more fundamental but unseen problem deeper in the tranny? Or does it sound okay to you? Anybody have a similar experience?

sasquatch · 02-10-2003, 11:48 AM

This is simple. Over time, clutch cables stretch. When you run out of adjustment, replace the cable. If not, look forward to failure of cable in near future.

AaronM · 02-10-2003, 01:38 PM

Yeah, there's a reason that you can only adjust the cable so far. Sounds like it's time for you to get a new cable. Adjusting the clutch can cure a lot of problems though. I adjusted mine and it cured my grinding problems.

Aaron

mikester · 02-10-2003, 01:50 PM

I bought the new cable FIRST, then I started adjusting the old one.

I want to replace it, but I haven't had time. Mine was only a little difficult and I had all the adjustment room in the world. I adjusted it about 3/8" and it was markedly better. I may adjusted it just a little more though.

It looks old, I want to replace it when I get some time.

Amark · 02-10-2003, 03:27 PM

On my car the cable goes through a 1" long brass bushing before the adjuster nut. If you are missing that bushing the cable will be too long.

I agree w/ mikester a 3/8" adjustment makes a big difference at the pedal.

Mark

73 2.0

RandyH · 02-10-2003, 03:37 PM

I was having the same grinding problem with 1st and reverse especially after the car warmed up. I was able to "adjust" the old cable which helped but the problem came back. The old cable had streched and I replaced it with a new Terry cable from PP and after installing it and making final cable adjustments at both the pedal end and tranny I no longer have the grinding problem.

Dave at Pelican Parts · Dave at Pelican Parts's Garage

Another possibility is that the clutch tube has broken loose either from the firewall or from the side of the center tunnel. If it moves, you will not get full cable movement. Open up the inspection holes and check with a flashlight and mirror to make sure the clutch tube isn't moving when you push the pedal...

--DD

Joe Bob · Joe Bob's Garage

All good suggestions....have ya checked the oil level/condition in the trans lately?