The Fixer

This question is regarding my 1983 MY with 65,000 miles;

For the past few months and some time after replacing the ball cup bushing the release lever pivots on, i can feel a click in the pedal or faint crunchy or knotchy feeling when letting up the clutch pedal when driving.

My car shifts well, i cleaned/serviced the clutch pack and reused everything as it all looked good. The ball cup bushing however was completely gone and was the only replacement.
I also gapped the 3 intermediate plate forks (i picked a value in btwn the tightest and largest gap).

This click is not in the pedal cluster,It feels like it originates within the clutch pack.
I was thinking since the ball cup bushing was completely gone for some time that the lever could have worn funny and that the click may go away at some point.
The car does shift well but as the clutch pedal is released and as i feel the click there is a very slight push as the clutch releases more abruptly.

Seems like a worn lever arm to me or slop in the lever arm. It does not happen 100% of the time maybe half the time.
It may be that my replacement bushing is bad already?

I had checked the ball pivot it was not bent and it was upgraded to the larger '84 part in 1984 along with the entire clutch mechanism by the dealer back in the day.

Is this click on take up something common and should i care? Thanks

Dave928S

How worn was the guide tube? If that had a step on it the release bearing could hang up on it momentarily and then get past the ridge/wear spot and release the clutch more quickly.

Rob Edwards

Worn grooves on the intermediate shaft or a 'shoulder' on the guide tube?

Dave928S

Here's what a new guide tube looks like ...

The Fixer

I do not recall how much wear there was, (I was completely new to the model at the time and was not tuned in enough) but if the b.c. bushing was completely gone that would increase wear on the guide tube.
That is probably the source. Should i rush to repair?

Mrmerlin

if you replace the guide tube then your going to have to replace the TOB and the release arm as the new guide tube has been replaced with a 928 GTS part and its slightly different from the older version as is the TOB and release arm.

SO a few things you could try.
remove the lower bell housing and put some grease on the guide tube, try to work it into the TOB sliding surface,
remove the bolts on the guide tube to add some extra movement to the tube.

Then turn it 180 degrees so the top is facing the bottom this may give the TOB a new surface to ride on

Next add a dab of grease to the tip of the slave push rod where it mates to the release arm cup.

Inspect the clutch pedal clevis and pin/bushings for wear, replace any worn parts

Dave928S

As the wear increases the clicking and catching will just get worse and more of a PITA. When it gets to be too much of a PITA you'll need to do something about it. An issue you should consider would be the safety aspect as it gets worse, where hesitation of clutch disengagement might cause unpredictable vehicle behaviour.

+ ^^ what Stan said.

The Fixer

^^^^ proof that there is no replacement for experience, thanks Stan and Dave thank you.

I like advice like this Stan, you're a real Mechanic, not a parts replacer.

Dave928S

And just for completeness, here is a pic of a guide tube with some wear. The wear/step will often be more pronounced at the top, which is why rotating 180 degrees as Stan suggested is likely to help.

Mrmerlin

I hope my suggestion cures the issue with the clutch,
and your welcome.
Thanks for the kind words!