Slave cylinder pushrod travel?

[js43lotus]

Can someone confirm for me what the actual slave cylinder pushrod travel should be (at the bell housing fork) on an 85 turbo? 

 

For full travel on the clutch pedal, with a new 5/8" master cylinder, a new 7/8" slave cylinder, 22mm adjuster nut setting, using both original rods (master + slave) and all the air bled from the line, I measured an actual slave cylinder pushrod travel of 11/16" (17.5mm).  That is not enough to actuate the pressure plate and shift into a gear while the engine is running.

 

Clearly, I need more travel at the slave cylinder, but I don't know how much I am short of the design spec.  Before I removed the old master + slave cylinders, the clutch operated fine.  Never thought to measure the travel before disassembly!

[andy b]

When i got the S3 Hc i had the same problem a rubbish travel and hard to select gears. i took the seat out I am a lard arse (can i say that) and found another hole in the pedal it was below the one used i had to adjust the push rod so it fitted (had to make it longer) Thus giving me more travel at the pedal. worth a look.

andy b

[Sparky]

I'd consider 17.5mm throw to be ample.  In fact, I believe the spec calls for less than that. 

[molemot]

Look at the adjuster....the big threaded thingy the slave cylinder pushrod connects to. This should stick out 22mm past the locking nut. Any less and you have lost motion..... The hydraulics are self adjusting, the slave cylinder piston changes it's fully back position as the clutch wears.

[js43lotus]

Sparky, if 17.5mm should be ample travel, but I cannot put the car into any gear with the engine running, could it be that the clutch plate is stuck to the flywheel?  The car has been on stands in my workshop for 8 months while I performed numerous repairs.

 

Molemot, the slave adjustment sleeve is set exactly 22mm beyond the locknut face, just as described in the manual.  It is with this setup that I achieve the 17.5mm travel.

 

Any additional thoughts?

[Sparky]

Yup, sounds like you need to free it off.  I'm sure you'll then find it's doing its job properly!

[RODOLPHESPRIT]

See this

[molemot]

I'm with Sparky....the clutch is stuck. There's a thread on How To Free Up Clutches on here somewhere....

[js43lotus]

Sparky, you were correct.  The clutch was stuck to the flywheel.  With the car on stands, revving the engine in gear (clutch pedal depressed) and slamming on the brakes, on the 3rd try the clutch freed itself.  Now works perfectly.  Drove the Esprit for teh first time yesterday.  Now new issues, but for another post.

 

Thanks for the advice, everyone!