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mgatlag · Joined: 02 Aug 2007 Posts: 647 Location: Avon, IN

Ok here's the deal. New clutch, TO bearing, pilot bearing, cable and had pedal mounts rewelded. Clutch works fine but the pedal is usually a little hard. Normally when car is cold. Then when it warms up a little, the pedal softens up a bit. Then every once in a while the pedal feels absolutely perfect for a few minutes. Then back to just a bit hard.
Both the cable ends are fine too and sits on the fork just fine. Can anyone think why this would happen?
_________________
Michael
'77 1/2 924 N/A- 5 speed Audi box
'04 Ford Taurus - gone!!
'92 Jeep Cherokee Laredo - gone!!

Porsche... better than tea with Miss McGill
(Slap Shot)

ManicCycle · Joined: 30 Sep 2009 Posts: 97 Location: earth

Did you grease the TO bearing and fork?

mgatlag · Joined: 02 Aug 2007 Posts: 647 Location: Avon, IN

Yea I greased them pretty good when I installed them. Wonder if I can get some more up in there through the access hole on the bell housing?
_________________
Michael
'77 1/2 924 N/A- 5 speed Audi box
'04 Ford Taurus - gone!!
'92 Jeep Cherokee Laredo - gone!!

Porsche... better than tea with Miss McGill
(Slap Shot)

Joes924Racer · Posted: Sat Jan 15, 2011 3:01 pm Post subject:

This may hurt if true... ya ready ok check the pedal assembly under the dash your looking for a cracked mounting bracket.
_________________
1979 porsche 924 Na
1980 porsche Turbo 931GT Replica
Have u ever driven a turbo.

fiat22turbo · Joined: 18 Jan 2006 Posts: 4040 Location: Portland, OR

How is the cable routed in the cabin?

How are the bushings for the pedal?

I would check the cable and the cable jacket just to make sure that there isn't binding there. Then the bushings and cable routing in the lever on the bell housing and in the cabin, on the pedal assembly.
_________________
Stefan
1979 924 Carrera GTS (clone-ish)
1988 944 Turbo S (Silver Rose)

mgatlag · Joined: 02 Aug 2007 Posts: 647 Location: Avon, IN

Well I just had the mounting bracket rewelded a month ago because it came loose and popped a weld. And the cable is ran just like it is suppposed to be and is not kinked at all.
_________________
Michael
'77 1/2 924 N/A- 5 speed Audi box
'04 Ford Taurus - gone!!
'92 Jeep Cherokee Laredo - gone!!

Porsche... better than tea with Miss McGill
(Slap Shot)

924RACR · Posted: Sun Jan 16, 2011 1:09 am Post subject:

Make sure the pedal bushings are all nicely greased.
_________________
Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

Slam · Posted: Wed Jan 19, 2011 2:06 am Post subject:

Bushings for fork in bellhousing? Worn fork? What the fork?

I mean the bushes where the fork rides in the housing (but you got that... AGAIN I'm wasting valuable typing resources).
_________________
'84 944 - kid blew motor
'83 944 - resting comfortably. For 12 years
'87 944 - sideswiped by trucker
'80 924 - gone
'78 924 - gone
'77 924 - rusting comfortably

mgatlag · Joined: 02 Aug 2007 Posts: 647 Location: Avon, IN

Man I really hope it's not those bushings. I'm NOT taking the damn thing apart again!! Maybe some carefully aimed shots of lube can help it out. Gonna do the ones at the pedal too.
_________________
Michael
'77 1/2 924 N/A- 5 speed Audi box
'04 Ford Taurus - gone!!
'92 Jeep Cherokee Laredo - gone!!

Porsche... better than tea with Miss McGill
(Slap Shot)

leadfoot · Posted: Thu Jan 20, 2011 2:22 pm Post subject:

two things that can affect the clutch quite considerably are the:
pedal return spring / which gives resistance to the depression of the clutch
and the cable sheath which can frey and jam over time causing alot of resistance.
Is it on the depression or release that is causing issues?
Stu
_________________
1981 ROW 924 Turbo -
carbon fiber GT mish mash
LS1 conversion in progress...

mgatlag · Joined: 02 Aug 2007 Posts: 647 Location: Avon, IN

Actually it's on both. But every once in a while it's perfect, for a short time...
_________________
Michael
'77 1/2 924 N/A- 5 speed Audi box
'04 Ford Taurus - gone!!
'92 Jeep Cherokee Laredo - gone!!

Porsche... better than tea with Miss McGill
(Slap Shot)

fiat22turbo · Joined: 18 Jan 2006 Posts: 4040 Location: Portland, OR

Going off of leadfoot's suggestion:

Take both ends of the clutch cable loose. Run the cable through the full range of motion, check for any frayed cable or rough spots. Move the pedal through its full range as well.

You may not notice bad pedal bushings with this method, but you might get lucky. At the very least, it might be worth crawling under the dash with a flashlight to watch the clutch pedal move to see if you can notice any play in the movement of the pedal that might cause occasional binding of the pedal.

If the pedal and cable check out, then you'll need to reassemble the cable, etc and open the inspection cover and watch the rest of the assembly move while you have someone operate the clutch pedal.

Spraying lube in that area could contaminate the clutch material and cause it to fail prematurely. So be very careful if you attempt this and use a small amount of lubricant and apply it carefully to the throwout bearing tube and the bushings for the lever arm. Use a thin paint brush perhaps with a white lithium grease.
_________________
Stefan
1979 924 Carrera GTS (clone-ish)
1988 944 Turbo S (Silver Rose)