Clutch Adjustment

[mickeytwonames]

I replaced the clutch several months ago and everything has been working fine. However, 1st gear started grinding slightly when I engaged it and today it was impossible to change any gear when the engine is running. The Clutch operates OK but the adjustment is obviously off. I have the service manual and I'm going to look at the 3/4 inch play on the clutch pedal as described in the General Data Section but is there any advice on what else I should be looking at?
Many thanks for any help.
Michael

[bmcecosse]

Go for nearer 1" free play. But as long as you have some play, it should be fine. Too much play means you may not be releasing the clutch completely. Also look under - is there any oil dripping at the jiggle pin?

[mickeytwonames]

Got underneath - made an adjustment - everything tickerty-boo - then crunch and the same problem - Ultimate diagnosis is that the weld on the NEW clutch lever joining it to the NEW shaft unit (unlike the separate parts in the manual) had failed and the pedal was moving separately of the linkage. I have now taken the old parts out and am girding me loins to replace the unit tomorrow- having got a replacement from Bull Motif.

Question: I've been told I can replace the shaft without removing the gearbox etc. I'm not convinced after offering it up - if I need some wiggle room can I slacken the wire tying the engine to the cross member and jack the gearbox up a bit without doing any damage?
If anyone knows of any other snafu's or shortcuts/tips please let me know.

[MarkyB]

The cross shaft with two lever arms can be removed with the gearbox in place, it's spring loaded on the gearbox side to give enough wriggle room when you remove the bush and housing from the chassis leg side.

[bmcecosse]

Well done finding the problem!

[mickeytwonames]

Back on the road - operation was a piece of brake .. I mean cake

[bmcecosse]

Can you post up a picture of the broken part - so all may learn......

[mickeytwonames]

This is the spot weld that broke between the clutch pedal and the link shaft - Lucky it happened at base and not halfway up a Welsh mountain - where I was recently[frame][/frame]. It seems rather a flawed design - just a spot weld on the end of a shaft that bears so much strain - if I had access to a welder I've have spotted the inside for extra hold. I thought of drilling through the pedal and shaft to put a pin in but ....BullM told me don't worry lightening doesn't strike twice... we'll see.

[simmitc]

The standard of new parts again = the original design was machined to a rectangular finish to provide the effort for twisting, and the weld was just to retain it. Of course a round peg in a round hole will be prone to rotate. Still, no doubt it's cheap

[bmcecosse]

Great picture - thanks !

[mickeytwonames]

And you don't know it's a round peg 'til it breaks - the weld on t'other side looked like a rectangular blob.