Getting pretty close to the end of my rope here so I'm hoping one of you has some good input. I think I've read just about every thread on here about clutch issues and adjustment.
Several months ago, while the engine was out, I noticed a small crack on the clutch release fork inside the bellhousing so I replaced it before the engine went back in. I have verified it appears to be oriented correctly. Lubed everything. While reinstalling the engine I also noticed the large clutch release arm had some wear, so I ordered a new one but in the meantime I reinstalled the old worn one. Adjusted the clutch to spec, although I never checked/adjusted the engagement range.
Fast forward a couple months of the car driving just fine. The clutch then began to feel like it was slipping a bit when engaging after a stop. Clutch was installed by previous owner about 20k miles ago, and I'm not terrible at driving a manual transmission. Then the pedal began feeling like it was sticking a bit when pressed all the way down. I figured, no big deal, I'll install the new clutch release arm and check the adjustment on everything.
I installed the new arm, including new needle bearings. Checked and lubricated everything. The stickiness at fully pressed did not improve. I then rebuilt the pedal cluster and decided I might as well replace the omega spring and assist spring on the gearbox too. I also installed a new clutch cable with a new clevis fork and pin. Clevis fork was installed at ~19mm. The old cable was about 10 years old. No joy, same stickiness still exists. I also went ahead and replaced my old original floorboard with a Rennline one since the old one was close to total disintegration.
Another point of reference: I can't get the engagement range to the spec of 25mm +/- 0.5mm. With the stop at the floorboard pushed all the way forward, I can get about 23.8mm of range.
When pressing the pedal, it mostly feels fine until it's pressed all the way down and feels like the cable may be binding in some way. Sounds like it too (watch the videos). I have checked the tunnel with my scope and don't see the cable hung up on or touching anything. I almost feel like this is the behavior I'd expect if the pedal were pressed too far, but I am still below the 25mm engagement range spec.
Here is my cable adjustment procedure:
1. Remove cable from large release arm.
2. set gap between bolt on small arm and the big arm to 1.2mm
3. Reattach cable and tighten nut on clutch cable to 1.0mm to preload
So to summarize, I have:
-Rebuilt pedal cluster including bushings, springs, etc
-Replaced clutch cable, clevis fork, clevis pin, release fork, large release arm and needle bearings, omega spring, small assist spring, floorboard, clutch pedal stop on floorboard
-Adjusted clutch one million times
I am wondering if perhaps lubing the new cable ("German" OE not Porsche, but had 911 OEM style sticker and purchased from Pelican) might help. Or adjusting the clevis fork? I'd really appreciate some enlightenment here, folks.
Here are some videos and pics:
VIDEO: Clutch cable etc on underside of gearbox:
https://www.dropbox.com/scl/fi/406xv0pn4svajx3nbhh3o/Gearbox.mov?rlkey=z340f3yxz54539fvm1uhtuunf&st=arqan3h9&dl=0
VIDEO: Pedal cluster:
https://www.dropbox.com/scl/fi/1515umfe253zky6mr66uq/Pedals.mov?rlkey=g0t1vbfxz4v72cnwilwfr3b39&st=sav3saay&dl=0
