xeps

So I finally got the car back on the road, after being on stands since October. Woohoo!

As part of winter maintenance I replaced the shift bushings, hoping to eliminate some notchiness during shifts. Thankfully, this removed 100% of the notchiness and difficulty getting into gear.

I have put about 300 miles on the car since then, and unfortunately the notchiness seems to be coming back - getting progressively worse. It may even be worse than last year at this point, going from perfect to fairly bad over the course of about 50 miles of travel.

Given that the shift bushings have just been replaced, the clutch slave bled, transmission fluid changed last year, and I'm on new wevo motor mounts - any thoughts?

I'm going to get it back on stands this weekend and take a look at the linkage, just in case something has worked loose. Any other ideas for things to check?

1990-964

Roll Pin? When mine failed it exhibited similar symptoms.

FeralComprehension

Replace the clutch slave and associated soft line; many many people (myself included) found this to make a significant difference. The clutch master too, if need be, though mine seems fine.

xeps

Forgot to mention that I replaced the clutch slave cylinder and hose reasonably recently.. 2 years ago now I think.

Roll pin visually looks fine, at least as much as I can see with the pedal cluster still in the car. I think I'll replace it anyway, along with the various bushings in the pedals.

993James993

When you say shift bushings, what do you mean? Are you talking about the nylon cups that the shift rod fits into? Perhaps one of them has come loose or was broken when you installed it?

FeralComprehension

Could be time for master, then. This stuff is old, and plastic bits don't last forever.

xeps

Those are exactly what I mean - the two plastic cups in the shift rod. My old ones were the consistency of well-chewed bubble gum.

Laker

which gear oil did you use?

xeps

Redline 75w90NS

Changed it last summer, so had some driving time before the most recent "winter" maintenance. Was much better when cold than it had been previously, with whatever was in the car when I bought it.

xeps

Managed to inspect the shift linkage today, and it was fine - no issues at all.

I also took the pedal cluster out, replaced the various bushings and roll pin, and replaced the clutch master cylinder. Haven't got the assembly back in the car yet, so no idea if the problem is resolved.

How do I accurately measure clutch travel, so I can make sure the pedal stop on the floorboard is at the correct spot?