Problem with clutch pedal

[iaintmaci]

I bought my 90 GSX last weekend from a guy who had NO idea what he was doing. Everything with this car was goofy. We have fixed most of the problems so far.
He told us the clutch needed bled. We spent about 20 minutes trying to bleed it when I realized it was a mechanical problem. Not a hydraulic. We attempted to adjust the clutch rod, and I ran out of adjustment. I could puch the pedal halfway to the floor before the rod even started moving. I decided to tear the assembly out. That is a fun job I'll tell you.
After getting the assembly out, I looked at the clevice where the clutch rod threads. Turns out the pin is worn a little, and the hole is worn ALOT. The hole was rounded out BIG TIME. I had about 1/4" of travel on the pin. This was allowing me to move the pedal almost 1/2 to 3/4 of the way down before it even started to push the slave. Having a machinist look at it this week wo see what he can do. Hopefully its not too far gone.

 

[90laserdsm]

my clutch pedal assembly was the same way. i got it welded and its been working great ever since.

 

[pauleyman]

The pedal part that the clevis slides through is replaceable. It also has a bushing in that hole if memory serves.

You can also replace that piece without having the drop the pedal assembly. Doesn't do any good if the pedal itself is worn (where it bolts to these piece) but if it's just the piece it can be done.

 

[iaintmaci]

I wasn't sure exactly what was wrong. That was why I dropped the pedal. The machinist at work is very good at what he does. It may be a free fix. Once I get this done, all I have to do is get the exhaust leaks fixed.

 

[asianandy87]

Yeah, my car had a grinding issue and I thought if was the tranny. turned out it was the clutch not releasing all the way

 

[Jbieke]

Hmm I'm having a similar problem with my 2g. I thought it was something with the slave cylinder, but after reading your thread it seems that what youre dealing with is quite similar to the problem I'm having. Please update after your machinist fixes the problem, I would like to know if this is a cheap/easy fix!

 

[iaintmaci]

Well, the machinist didn't get a chance to fix the problem, but told us how to do it. We drilled out the egged shaped hole so the center of it would be where the center of the factory whole was. This would put the pin in the same position. He gave us a brass pipe fitting to make into a bushing. I cut it down to be just a little shorter than the inside of the clutch rod clevice. I made the hole in the clutch lever just big enough to fit the homemade bushing snuggly. I found a grade 8 shanked bolt that fit perfectly through the brass bushing. It fit snuggly, without any slop or drag. I was able to find a bolt that the entire shank was long enough to clear the clevice. I cut the threads off and tapered the end of the new "pin" so it would easily go through the assembly. I then drilled a hole through the bolt to insert a cotter pin. Reinstalled the factory plastic washer with the pin. I used a light coat of grease inside the bushing and on the pin when I assembled. It is in the car now and working good. I still need to adjust it, but no more grinding when trying to put it in gear.

Sorry for lack of pictures. I have a couple from the project. When I get them loaded somewhere I will add them in.

 

[SY1100]

I believe busher offers a replacement/upgrade fix for this as well. I think you send thema core and they send you a new for a 100 bucks.

 

[iaintmaci]

I looked into getting a new assembly from shep, but I figured I would attempt this for now. Free is better than $100+ dollars at the moment. I was wanting to make sure I was able to get the car road worthy before sinking to much into it. When and if this repair fails, I will probably just get a set from Shep.