Gear Grinding 1st & Reverse, When Engine Warm (Page 2/2)
Doug85GT JUN 05, 01:01 AM

quote
Originally posted by Patrick:
Are you referring to the bushing in the banjo? Didn't your replacement master cylinder come with a new banjo? If so, how did it wear out in 4k miles?
If it was my car, I'd want to find out why my clutch pedal alignment was different than everybody else's!
It's the steel part that bends! How much higher is your clutch pedal than your brake pedal? It's supposed to be an inch.




I don't believe the bushing wore out in 4k miles. I think it was loose when I installed it and I just did not pay attention to it.

I am not sure if my car does have a different geometry. I read through a few threads that mentioned banjo up vs down. The best reference I saw was someone quoted Archie. I did not see anyone actually measure the difference. I measured the difference and based on that I will have my banjo down until I get the new bushing at which time I will measure it again. Even if my car has a slightly different geometry, I have neither the time nor patience to try to figure out what the proper dimensions of the structural members are on my car and whether my car falls into factory specs.

That U piece of my clutch pedal is straight. I measured the top of the U and the bottom and they were the same. The bottom is at a 90 degree angle to the part of the clutch pedal it is attached.
Patrick JUN 05, 01:25 AM

quote
Originally posted by Doug85GT:

I don't believe the bushing wore out in 4k miles. I think it was loose when I installed it and I just did not pay attention to it.



There are two different size banjo bushing/pedal assemblies. Perhaps you had them mismatched.


quote
Originally posted by Doug85GT:

I am not sure if my car does have a different geometry. I read through a few threads that mentioned banjo up vs down.



I've noticed on my Fieros that if the banjo loop was down, the angle of the banjo in relation to the master cylinder was **** -eyed when the pedal was pushed to the floor. Not so with the loop facing up. Anyway, do what works for you.
reinhart JUN 05, 08:30 PM
Interesting observation. While I've always heard the banjo loop needs to be up, I've never actually heard of anyone that measured throw with it up vs down before. I'd like to hear from anyone else that has measured both ways and what the measurements were.
pmbrunelle JUN 05, 09:19 PM
The effective length of the banjo pushrod is measured from the banjo hole to the spherical (or is it conical) tip which pushes on the master cylinder.

This effective length remains the same whether the banjo is up or down. (No effect on throw)

With the correct banjo orientation, the rod remains better-aligned within the bore of the master cylinder. So, the rubber sealing boot works better, and there is perhaps less risk of the banjo rod scratching the inside the master cylinder.

[This message has been edited by pmbrunelle (edited 06-05-2023).]

Doug85GT JUN 10, 11:26 PM
Update

I installed the brass bushing. It made no difference. It did not take up the slop in the pedal either. There is still about a 1/4" of wiggle up and down. Since I never noticed it before I'll just live with it since it does not seem to affect how the clutch functions.

This time I measured everything myself. Last time I had my wife do the measurements as I pushed the pedal in. I used my truck bed load bar to hold the pedal down as I did the measurements. There was no difference in the travel distance with the loop up or down. I left it up. I'll blame the erroneous previous reading on my wife.

I replace the slave cylinder. It was just $18 so I figured why not. It made no difference in the travel distance. I am still at 7/8" travel. I used V8 Archie's bleed method including pushing in the slave rod with the bleed screw off. No additional air come out on that step for me.

At this point, I don't think 1 1/8" travel is attainable for my car. I'll just live with 7/8".
Trinten JUN 11, 12:10 AM
I hope the bleed process fixes it for you.

I had that issue with my last Fiero, after it got hot, going into first became impossible when the engine was running. I'd have to kill the engine, put it into gear, then hold the clutch down and start the car.

After it was bled again later, the issue went away.