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Derek:
Gear selection with engine off is flawless with or without cluth pedal depressed. Pedal does seem to have a light/heavy/light sequence on depression but it is _very_ subtle and takes much concentration to become apparent.
Clutch fork movement is 3/4" to 5/8" from rest. With clutch out the fork is resting on the slave cylinder rod adjusting nut and the fork can be forced by hand about 1/8" toward the back of the car.
I've actually gotten used to extremely wobbly shifters in old Volvos. Both our previous 544 and this 122 had a good six to nine inches of play at the shift knob while in gear. This issue is quite different from not being able to locate gear positions while shifting. The latest trans with a tight brass pivot is actually kind of weird feeling.
A new clutch, resurfaced flywheel, release bearing and pilot bearing were installed about 15 months ago. This is a daily driver so its also travelled 25,000 miles in that time period, often with stints of 5 or 10 miles of stop and go traffic. Even so, the previous clutch, of unknown age, lasted more than two years under same driving conditions before needing replacement. It may be that the last clutch job was not done properly.
Current plan is to replace clutch, release bearing and pilot bearing (DIY). It will be easy enough to replace the slave cylinder later if the clutch replacement doesn't resolve the hard shifting issue.
Thanks for helping,
Joe M in WV
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