Originally Posted by
Luva65wagon
The things I can recall seeing over these many years on these old Falcons to cause a clutch issue are:
1) Hole in the clutch rod, under the dash, where there is no bushing, but is a wear point, the hole in that rod or the pin on the clutch pedal are just worn to beat all. A combo of both will give you that run out of thread issue.
2) the Z-bar bushing at the frame or on the side of the block are worn or gone causing the Z-bar to be a rattler - causing too much play in the system causing that run out of thread issue.
3) The clutch rod at the transmission , which also has a hole and a pin engagement deal with no wear bushings is worn to beat all and causing the run out of thread issue.
4) The clutch rod at the transmission is bent or the wrong one bringing the center point of the thread issue to be off center.
5) The clutch lever into the bell housing, where the clutch rod "point" sits in the indentation well, which is a wear point and can over time have the well go deeper, can cause the run out of thread issue.
6) I've had a faulty rebuilt clutch pressure plate (both "new" out of the box) on two occasions where the the three lever arms on the clutch do not equally relieve the clutch disc (the pressure plate releases cattywompus like) and you adjust the thread to the end and yet it never fully releases though the movement of everything should be more than enough. This is hard to diagnose. I only know to test it with the transmission yanked. Of course I know 1-5 above are not the issue first.
There may be others that come to mind. A guy's been at this a long time and may forget a thing or two along the way. Ultimately, knowing for sure whether the clutch is in fact disengaging is the key here before even thinking about transmission internals.
The fact you have now no further adjustment on the clutch rod says to start at #1 and see whether there are wear issues.
Could be the engine, where it was sitting before the work began, worked in your favor to negate any "wear issue" results, but in the correct position (assuming now is the correct place) reveals them. But wear points are easily checked, but not easily remedied. Most of the ones I've encountered required some welding and grinding to restore lost metal.
Just breathe and be systematic and I'm sure you'll have that ah ha moment - THERE IT IS!
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