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Discussion Starter · #21 · (Edited)
Got time for another clutch question?
After a test of my patience I have everything back together. Stop and switch(s) adjusted. Final adjustment would be at the bell housing. The threaded part of the cable [kind with the rubber, not two lock nuts] is too short as it is. I run out of slack at the clutch lever about 1/2 way through the radius-ed end nut . I found the little mark on the clutch shaft end and it is beside the one on the arm. The clutch seemed good and no hint of a problem until the switch pedal arm cracked enough to not hit the pedal position switch. Pedal weld to the shaft was starting to crack but had not let go yet and the cable arm square is in the same spot it was (saved most of the square hole and only had to file the welds). Any suggestions?
Edit1- I altered this after I blew the pic up enough to see both dimples so it is in correct position. In the morning I'll triple check that the shackle is correct on the arm, as that is all I can think of.

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Discussion Starter · #22 · (Edited)
Early this morning I took the cable off and reinstalled it. The shackle is seated on the arm correctly and seated on rubber by bell housing. Can tell by the threaded end it was never cut. It worked when the pedal arm was cracked so WTH? It may have been set with a higher pedal? In the short term, is there a compelling reason I can't adjust the clutch release arm on the splines until the new OE cable arrives ?
 

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Discussion Starter · #23 ·
Tried moving the release lever on the splines and got lots of thread showing through, possibly too much. Clutch did not disengage so I moved it back to the original marks. Very little slack at lever, guesstimate at 1mm and brake pedal free travel down to about 1/2". Started the car with 4 wheels in the air and the clutch is dragging?

Brake off, clutch in = wheels spin.
Brake on, clutch in = wheels stop and motor doesn't notice.... but going into reverse a bit reluctant. So clutch has a little drag.
Tried to get a bit more clutch pedal travel and can only gain a very little before the pedal stop bracket contacts the metal bracing. As the bracket was smashed down before, this wasn't an issue. Was that why it was smashed? I am getting about 1" of travel at the release lever so may be a bigger issue hiding.
Best to wait for the new cable and start there.
 

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99 Tracker, 5 door, 2L, 4x4
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Haven't read the whole thread again, but have you verified that the pass through on the firewall is not compromised..
 

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Discussion Starter · #25 ·
Yes I double checked it.
Between the broken pedal arm and the, smashed then jerry rigged, pedal stop I'm concerned about what things the PO has done. New cable, I hope, will give me a starting point. Starting to consider something wrong in the clutch itself.
 
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