jfakiris

The nylon bushing on the top of the clutch release lever was gone, and I am trying to install a new bushing. I removed the airbox assembly and I could see the lever and the pivot ball on the top of the bell housing, but no nylon bushing. I then unbolted the clutch slave cylinder and pulled it back, allowing the release lever to move. It was then easy to push the clutch release lever back and off the pivot ball and push it slightly to the left (the passenger side).

The problem I have is that the lever does not go back far enough to clear the thickness of the nylon bushing, so I cannot push the cup over the pivot ball, or insert the cup inside the lever cavity first, and then push it over the ball. The clearance is less than 1/2 inch, which is less than the thickness of the nylon cup. I can feel an up and down motion, but cannot push it backwards towards the firewall and away from the pivot ball. The lever seems to come to a hard stop and I do not want to really force it as I am afraid that I will break something. I read in a user's link that it can be done from the top without removing the clutch assembly. Will the lever move if I push it backwards very, very hard without breaking something? Any other suggestion?

The pivot ball is 19mm, and the car is 1981 with a 5 speed manual transmission.

Thank you,

John Fakiris.

Scott Turnbull

As long as you have the slave disconnected you are OK. Insert the nylon bushing into the arm not over the ball. Then use small prying devise to leverage the arm back and over the ball. There should be nothing in the way of the arm moving backwards. The resistance you are feeling should only be the pressure plate springs and they will give more than enough to get the arm and bushing over the ball.

worf928

What Scott said. You're feeling the release arm lever wanting to begin pulling on the throw-out bearing which is mounting in the pressure plate fingers.

FlyingDog

On mine the ball would not go into the bushing with the bushing in the arm. Take off the slave cylinder and lower bell housing, rotate the release arm so that the top moves to the passenger side, pop the bushing onto the ball, rotate the release arm back over the bushing and slide it on, then reinstall the lower bell housing and slave cylinder. The only prying force you need is to push the bushing onto the ball. I used a long thick combination wrnech against the firewall. Once the get the angle right, it requires little force.

If you have MSDS headers it will be a PITA to get the bell housing oriented to a place where the release arm can rotate far enough to get the bushing on the ball.

tammons

You can get it in, it just takes some patience. I forget exactly how i got my last one in, but it seems like I had to jam it between the ball and the opening, and force it in with a prybar.

Something like that. Its a real PIA though.

Garth S

Check out the tightness of the ball stud while you have an opportunity: on WSM 30-21, there are the four versions that were used. My 1980 release lever nylon cup was replaced because the M6 threaded ball stud snapped off. Not sure if you have the upgraded part in an '81.
If you ever have to replace it, the newer M8 threaded stud is the one to use .... although it's a little more work to access ..

whall

Replaced mine using a prybar and patience - pretty simple job really - or I got lucky...

jfakiris

Thank you all for your replies. I tried again pushing in the nylon cup from the top, but no luck. The space between the ball and the arm socket is too narrow and I cannot push the cup in. I am attaching a picture that shows the problem. I am puching the release arm with an 18' screw driver that I thinned to fit the slot. Any suggestions to avoid dropping the bell housing will be appreciated.

Thank you.

UKKid35

Once you get the nylon installed in the arm (which looks difficult in your pic), no need to pry the arm back on, reinstall clutch slave and use gentle pressure on the clutch pedal while an assistant ensures correct location of arm/ball.

tammons

Seems like the last time I did it, I had to slide my fork down and wriggle the nylon cup into the arm with one of those two finger impossible moves. A bit dicey at the least and I dropped the cup once, managed to find it, and finally got it in.