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Old 06-14-2012, 02:37 PM   #1
Gregsenne
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Join Date: Sep 2010
Location: southwest ohio
Posts: 82
Clutch linkage problem

My 1986 1/2 ton truck used to be an automatic, and I put a SM465 4 speed in it. Trans, pedal set, and manual linkage are all from a 1979 1-ton truck. There is an extremely heavy helper spring under the dash for the pedal. There is a return spring from the clutch fork to the frame rail. There is a spring holding the Z-bar to the clutch fork. I had to use a piece of all-thread for the clutch fork pushrod because the factory one engaged about an inch from the floor, with the pushrod adjusted all the way out. Using allthread let the pedal engage about halfway through.

The problem I am having is the pedal does not return all the way back, and I can pull it the rest of the way up with the tip of my boot. It seems like the helper spring (in the cab) is overpowering the return spring.

So I removed the helper spring as some people suggested, but now it hurts my leg after driving in town for more than a few minutes. The pressure plate has some serious spring to it! I understand why there is a helper spring! But, with the helper spring removed, the pedal does return all the way up.

So does anyone have any suggestions? I hate to drive it without the pedal returning all the way, it makes me feel like the throwout bearing is riding the pressure plate (which would cause premature failure). Not to mention that every car or truck I've driven since then, I find myself wanting to pull the pedal back up inbetween gears, when it is already up! Switching to hydraulic is not an option, I'm poor!

Thanks for the assistance.
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