Clutch disengagement/travel distance changed

[shu513]

I've been trying to figure out the problem and hoping to find the solution for my recent issue with clutch disengagement distance change. I'd really appreciate your opinions from your previous experiences!!


I did not have any issue until last weekend when I took my notchback out to a short cruise. On the way back from coffee shop, without any symptoms the clutch disengagement point got much closer than before. And the pedal resistance became little lighter (less resistance) than before. It just does not feel right.

The pedal distance when riding the clutch was much larger before, but it feels like once it starts to engage it fully engages right away. The car runs and goes into all gears without grinding (clutch fully disengaging), and it does not judder or make any noise at the engagement. The cable where it is visible at the operating lever looks fine (the cable is about 3 years old), and bowden tube has proper sag. Clutch is not slipping. There is a clicking noise from around the clutch operating lever on the transmission when I fully press the pedal down to the floor. No noise can be heard from pedal assembly or inside the tunnel.

The pedal free play has little resistance, and it has more resistance after about 15mm of free play, so I am thinking adjustment is ok. I can loosen the cable more and see what it does to the clutch engagement, but my thought of loosening the cable will just increase the free play, not adjust the engagement/disengagement distance.

I am hoping that fixing this issue will not require to take the engine out...

Please advise. Thank you in advance.

[W1K1]

sounds like something is giving out, can you get a picture down the tunnel? or pull the pedal assembly, it sounds like the hook or cable at the pedal end

_________________
1973 super 2110cc
1965 squareback 1500E-sold
1971 bay window westy- EJ2.5 subi swap

[KTPhil]

The normal degradation/failure is for it to take MORE travel to disengage the clutch, not less.

Still, I'd pull the pedal assembly (a real greasy PITA), and make sure all is clear there, because the next step is an engine drop.

[shu513]

I really appreciate your inputs, KTPhil and W1K1.

I Just pulled the pedal assembly and inspected the hook and cable.
They both look ok to me.

Before pulling the assembly out, the cable play was adjusted/loosened. As I mentioned it increased free play to more than specified, but nothing else did change.
I could not take pictures of inside tunnel, but I felt the tube where cable goes in, and it was solid/did not feel loose.

Therefore, my assumption is that there is something wrong with the clutch components, unfortunately...
Could it be the throw out bearing? throw out shaft? pressure plate? worn out clutch disk?
I'd really appreciate if you could tell me what usually happens if each of those components go bad.

Thank you for your help.

[_Pascal_]

I am sorry I can't be of help to you but you could really be of help to me. Could you perhaps measure the distance between the gas pedal mount and the first bolt hole as marked by the red arrow below?

[shu513]

[_Pascal_]