Clutch Disengagement Issue - 1971 T2

[GusBus1971]

A month ago the clutch pedal lever on my 1971 T2 Bus worn down and broke due to the PO installing a threaded bolt and not a smooth pin.

I replaced the pedal lever, lever pin, Bowden tube, and the clutch cable.
I have screwed the clutch cable wing nut all the way to the Clutch cable arm.

The issue is when I press the clutch pedal down completely to the floor, I can't select gears without a loud grinding sound and when I am able to force it into 1st the bus jerks forward and stalls.
Another symptom that occurs is when I push the pedal down the pedal doesn't come back up unless I manually put my foot under it and pull up.

Any suggestions on next steps or should I go about replacing the clutch plate?

[aeromech]

Well, my first guess is that either your new cable is too long or maybe you need to shim the new Bowden tube. I’m guessing from your description that you have a huge amount of clutch pedal free play. It should be about 3/4 inch or so. Also, you could have welded up the worn through hole in your pedal assembly and eliminated a lot of guess work here.
_________________
Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
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Capable of leaping tall buildings in a single bound

[skills@eurocarsplus]

keep forcing stuff and your second post will be where to buy a transmission.

sounds like your clutch adjustment is WAY out of whack. only you can figure out why
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[aeromech]

It seems pretty straight forward. You found a broken part and replaced it. Problem solved. Nope, because you then changed other parts too and now we have to guess what you did wrong. It’s not an engine pull and clutch change. You replaced the broken part. Don’t make things worse. Go back and look at what you did already. Did you know that the part you replaced, the one with the torn out hole, can be installed backwards? There are drawings of it here on the samba. Search
_________________
Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound

[SGKent]

[aeromech]

That’s it. Thanks Steve. I’ve installed this backwards. I can’t say it’s your problem though but it will cause your cable to break early
_________________
Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound