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Old 10-30-2021, 04:09 AM   #1
Neil Mylar LakewoodCA
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Default Clutch pedal play was 1", now it's 2 1/2". What happened?

I installed a rebuilt transmission in my truck, 2 years ago. At the time I adjusted the clutch pedal play to be about 1 inch.
I've only driven the truck 4 or 5 times, since then. The last time I drove the truck, the transmission kept grinding. I recently check the clutch pedal play and it's 2 and 1/2 inch.
What could have caused this sudden change? I am going to attempt adjusting it tomorrow.

Thanks in advance.
Neil
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Old 10-30-2021, 05:02 AM   #2
nkaminar
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Default Re: Clutch pedal play was 1", now it's 2 1/2". What happened?

Take the transmission cover off and see if the throwout fork is seated correctly in the notches in the throwout bearing housing. The fork is sometimes not seated correctly when first installed and then snaps into proper position. Other times it has to be manually positioned correctly.

There could be something else wrong, but this is the most likely cause.
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A is for apple, green as the sky.
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My car grows red hair, and flies through the air.
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Old 10-30-2021, 05:45 AM   #3
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Default Re: Clutch pedal play was 1", now it's 2 1/2". What happened?

Your clutch lever arm probably failed. It's common. Take a peek under.
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Old 10-30-2021, 06:28 AM   #4
Mike Peters
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Default Re: Clutch pedal play was 1", now it's 2 1/2". What happened?

Yep. Clutch arm X2. They crack and break at the pin hole. It's a weak spot.
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Old 10-30-2021, 08:27 AM   #5
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Default Re: Clutch pedal play was 1", now it's 2 1/2". What happened?

All of a sudden! most likely cracked clutch arm. X-3
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Old 10-30-2021, 08:46 AM   #6
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Default Re: Clutch pedal play was 1", now it's 2 1/2". What happened?

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"I've only driven the truck 4 or 5 times" in two years

There's the problem, she what's to be driven more
As Grandpa always said..."The more you drive them, the better they get"
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Old 10-30-2021, 09:14 AM   #7
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Default Re: Clutch pedal play was 1", now it's 2 1/2". What happened?

Mosy likely failed, broke, deformed clutch linkage. Less ikely - pressure plate coming loose from flywheel. Looking through the inspection cover should tell all.
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Old 10-30-2021, 09:19 AM   #8
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Default Re: Clutch pedal play was 1", now it's 2 1/2". What happened?

As others have said, clutch release arm.
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Old 10-31-2021, 12:17 AM   #9
Neil Mylar LakewoodCA
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Default Re: Clutch pedal play was 1", now it's 2 1/2". What happened?

The clutch release arm is the newer stronger solid version. The pressure plate fingers are not equal distant from the throwout bearing.
I adjusted the pedal distance to be around one inch.
The transmission does go into first and second gear without grinding.
I will drive the truck tomorrow to test it out.

Thank you everyone for your suggestions.
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Old 10-31-2021, 12:40 PM   #10
Dick M
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Default Re: Clutch pedal play was 1", now it's 2 1/2". What happened?

I agree it is usually the clutch arm. However, I would also check the return spring on the throw out bearing to see if it is in tact.
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Old 10-31-2021, 01:18 PM   #11
nkaminar
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Default Re: Clutch pedal play was 1", now it's 2 1/2". What happened?

I can see the release spring in one of Neil's photos. Looks intact.

I stand by my comments in post #2. I have seen this twice, one on someone else's car and once on mine. The fork that pushes on the housing for the throwout bearing sometime does not engage the little detents in the housing properly. The fork can then snap into position later on. This will cause the clutch play to go from 1 inch to 2 and a half inches.
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A is for apple, green as the sky.
Step on the gas, for tomorrow I die.
Forget the brakes, they really don't work.
The clutch always sticks, and starts with a jerk.
My car grows red hair, and flies through the air.
Driving's a blast, a blast from the past.
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Old 11-01-2021, 11:21 PM   #12
Neil Mylar LakewoodCA
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Default Re: Clutch pedal play was 1", now it's 2 1/2". What happened?

I drove it on Sunday. It goes into first gear without grinding, but it does grind when double clutching into second and third.
It grinds even if I did not double clutch, but just waited longer to put in gear.
I plan on replacing the pressure plate some time soon.
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Old 11-01-2021, 11:29 PM   #13
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Default Re: Clutch pedal play was 1", now it's 2 1/2". What happened?

Quote:
Originally Posted by Neil Mylar LakewoodCA View Post
The pressure plate fingers are not equal distant from the throwout bearing.
Have you tried adjusting the pressure plate so the 'fingers' are even?
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Old 11-02-2021, 06:41 AM   #14
nkaminar
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Default Re: Clutch pedal play was 1", now it's 2 1/2". What happened?

I believe the spec on the pressure plate fingers are +/- 0.005 inch. Close tolerance on these babies.
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A is for apple, green as the sky.
Step on the gas, for tomorrow I die.
Forget the brakes, they really don't work.
The clutch always sticks, and starts with a jerk.
My car grows red hair, and flies through the air.
Driving's a blast, a blast from the past.
nkaminar is offline   Reply With Quote
Old 11-02-2021, 10:59 AM   #15
richard crow
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Default Re: Clutch pedal play was 1", now it's 2 1/2". What happened?

check the pin that goes through the release fork. also the pin on the release lever
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Old 11-02-2021, 11:31 AM   #16
Patrick L.
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Default Re: Clutch pedal play was 1", now it's 2 1/2". What happened?

The pressure plate finger height difference is .002". But at .005" the difference won't be noticed.

When setting the fingers in the vehicle I mark the finger that contacts first and work off that one with a long .0015" feeler strip.
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