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Repost: T5 conversion question 140-160

So your problem is that you can't disengage the clutch because you don't have enough throw at the pedal?

The 1st step is to look at the diaphragm in the pressure plate. For example, if the clutch plate is too thick, the diaphragm will go over centre & when that happens it becomes nearly impossible to put enough travel into the clutch cable to get the clutch to release. The fix is to space the diaphragm out with some good washers placed between the pressure plate & the flywheel.

Next step is the clutch fork pivot point, that depends on what flywheel, clutch & pressure plate you are using, you can set it up like the pressure plate, but you can go over centre with them.

Finally, if you are happy with how the clutch works, but have run out of threads on the cable adjustment you could just put both nuts on the same side, or bend the outer end of the clutch fork in to a chicane shape.






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