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I have almost finished the 5-sp overdrive conversion to my '73 tii. As the trans tunnel is a bit tight I have knocked it out a little to accommodate the slave cylinder on the 5-sp box, and installed the bleeder up in the engine bay for easy access (250 psi flexible nylon line from master to slave and back to bleeder). The system seems to be properly bled (no bubbles even though the outlet of the master cylinder point downwards making the job fairly frustrating to say the least) but the clutch pedal has little feel until it is pumped a couple of times. I have the car on stands and once pumped right up the clutch gradually grips, with the pedal right in. I have just had the FAG Schafer master cyl resleeved and I suspect the problem is the new ATE slave cylinder which seems to have a larger bore than the original FAG cyl from the 4-sp (thus the rod pushing the clutch release arm moves less than on the smaller diameter 4-sp slave). I realise that the release arm on the 4-sp protrudes from the housing and is longer than on the 5sp so it would need more rod movement.
Anyone have any suggestions? I have looked through the archives with no luck.
As I see it I have a couple of options - either install a different master cylinder with larger displacement, reduce the bore of the new slave cylinder or lengthen the rod which moves the release arm.
Could it be a case of different OE brand items being incompatible in their diameters?
How far does the end of the release arm have to move between engaged and disengaged in the 5-speed?
This is the last thing keeping me off the road, I hope! Thanks in advance.
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