"Pump Up" After Correct Adjustments... Before installing new clutch.

[Red 4G63]

After searching and reading many of the "Clutch Adjustment" threads, none of them seem to answer my questions or problem. I'd also like to see if anyone else has had the same problems as I have, and any possible fixes.

I bought the car last Oct. (2009), the gentleman whom I purchased the car from told me that it would be needing a clutch, in the near future, due to the fact that it seemed to be warn. The pedal never really felt right and the engage/dis-engage points were all over the place. Never seemed to make a difference if it was hot or cold. The clutch M/C had been adjusted all the way out, prior to me purchasing the car, which led the Push Rod to bend one day while I was taking the car for a ride. After getting it back together (in the middle of the road), I limped the car home and stuck it in the garage for the winter. I got lucky, it was the last nice day of fall, last year.

I purchased a new M/C off Ebay and installed it. The rod seemed to be longer than the M/C I removed and the pedal wouldn't line up right. I adjusted the rod all the way into the pedal (counter clock-wise) and it still wouldn't line up to the pedal. Which led me to pushing in the rod, just a little bit to get it to line up and install the cotter pin. This, obviously led me to have "Pump Up".

After reading many articles about this issue, I began to understand how "Pump Up" works. I could not budge my S/C and the M/C rod was adjusted all the way into the pedal (away from the firewall). I then took a close look and noticed that the Clutch cruise switch bracket had been bent down, towards the firewall for the last M/C, because that rod was too short. So, I bent the Cruise Bracket back out away from the Firewall, then everything started to line up perfectly. The S/C rod was now allowed to be pushed into the Cylinder, as it should, allowing fluid to travel back into the Resevoir, via M/C bleeder valve being open. I began to make adjustments on the M/C rod until the S/C wouldn't budge, and then back out (tiny adjustments) until it would move. The car shifted perfectly! Engagement was 1/3 of the way off the floor and the pedal had the necessary play in both directions. I took the car for a cruise and it shifted great.

Now, comes the problem. I took my GF for ice cream and it was a little chilly outside. So, as we chilled in the car, I started it up to get some heat going and warm up. We maybe sat ther for 15 mins, with the car running. As I began to push the pedal down and put it in reverse, the pedal seemed to be in "Pump Up" mode! I was baffled. I know brake fluid expands, but I thought I had it adjusted to relieve that problem? After driving it home, the pedal returned to semi-normal. I'm hoping for the quick fix, of a little more adjustment....? What do you guys say/think?

I really don't want to install the ACT2100 and Streetlight Flywheel this early in the game, as I was hoping to wait and enjoy the summer a little. I wanted to wait until winter to drop the Tranny. Hopefully having a little more money by then, so I can replace the Clutch fork and Fulcrum, while I'm in there.

Any Feedback, will be appreciated.

Thanks!

 

[FLASH1970]

If you take apart the clutch master cylinder you'll understand why "pump up" occurs. What I did what take the slotted piston and drill out the slot to be bigger, then I drilled out the bolt hole to be bigger and re-tapped it. This way I could put a bigger diameter bolt in so it would contact the relief valve sooner. Problem solved. I should have taken pictures when I did it.