The important things with clutch adjustment

1. Must be some free play so that clutch doesn't slip. Any amount is enough, even 1mm play. The spec of 11-15 mm play at the pedal allows for wear so you won't need to adjust it every day (maintenance schedule says adjust every 6,000 miles)

2. Must be enough pedal travel so that clutch engages fully. Spec is minimum of 136.5 less 15 mm (115.5 mm pedal travel, at least). If you don't have this much movement after the play is taken up, it can grind gears, or sometimes not even go into gear

If you have it adjusted adequately and it goes into each gear smoothly while stopped (engine running), the clutch is OK. If it then grinds while shifting only when the car is moving, that would be bad synchros

Good questions.

* 12 mm at pedal is OK (need at least some play to prevent clutch slip)

* Free play at the transmission is how much the arm moves without using leverage (no tools)

Should move about 3-4 mm -- push the lever towards back of car, then pull forward (with moderate force). It is adjustable, but not at the gearbox. The adjustment is at the firewall and at the pedal

UPDATE: pedal height spec is 136.5 to 146.5 mm

Clutch Cable



1. Adjust the pedal stopper so the pedal height is in range from 136.5 to 146.5 mm (5.4 to 5.8 in), and secure the position with the lock nut completely

2. Next, adjust the control cable adjust nut so that clutch pedal play is in range from 11 to 15 mm (0.433 to 0.591 in) at the center of the clutch pedal pad, and make sure that play at "P" point of the withdrawal lever is in range from 3.0 to 4.0 mm (0.1181 to 0.1575 in). Secure the alignment with lock nut completely.

Attach file:

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  Factory Service Manual CL-07.jpg (121.80 KB)


  Factory Service Manual CL-08.jpg (78.04 KB)

Hey... I've adjusted the free play to around 12mm but is there any way to adjust the cable at the transmission?
I'm not sure if it is correct...
There's a little bit of play but I'm not sure if it is play as I'm comparing the amount of pressure needed to move it to that of the clutch pedal... Is it harder to move the arm on the gbox than it is to push the pedal....

Also... Does free play at the arm mean the cable travel before it pulls the arm or how much the arm moves with not a lot of force required.

Cheers.

Yes, you might have missed my posts above where I talked about that

So the combo is correct... Doesn't grind into reverse or any other gear when stationary...
Could pedal free play be the reason it has a bang out of the gearbox when releasing the clutch to take off in first?

So I have a 120mm pad height...
I'll test what you just told me.

Oh yeah, there are two adjustments at the pedal end:
* small stopper at pedal to adjust the pedal height
* large nuts at firewall to adjust the cable play

40 mm free play is the problem, it will limit the pedal travel after the clutch starts to move


Measure as shown in the diagram


Does it grind when parked, engine running, clutch pedal down, and shifting into various gears? Try REV because it doesn't have a synchro

* If it shifts in and out of REV with clutch pedal down, then the combo is correct
* grinds on all gears with clutch pedal down, not enough pedal travel (pedal stroke)
* only grinds when car is in motion -- bad synchros

Okay so transmission has 3-4mm
So pedal has about 40mm of free play :/

also do I measure pad height from the floor pan starts to rise up towards the dash?

3-4 mm is excellent and it means the clutch is releasing all the way


But if there is not enough stroke, it will grind when changing gears