So... after having my clutch replaced with the Exedy HD variety the missus complained that it was a bit hard to work...
So I performed the "Clutch Adjustment" mod... this improved things, but not much... I noticed that when adjusted in too far the pedal would "stick" abut 3/4 of the way up before popping up the last bit... thought this was just one of those odd things and adjusted the pedal to the point above where this happens (2.5 turns in from std)... I also noticed occasional slow return of the pedal at the upper end of the movement, which got a little worse over time.
Next up I bled the clutch hydraulics, this made a HUGE difference, clutch becme much more friendly and all pedal slowness or stickiness dissapeared! There was one thing I thought odd... with the bleeder nipple open the pedal pulled itself down to the floor when pushed down a little. Once pulled back up to the "inflection" point it would pop back up under spring pressure.
However over the next few weeks the pedal stickiness returned, getting to the point of being annoying, so I bled the clutch again, which made no difference this time... Then I noticed that I had used DOT4 brake fluid (both times), instead of DOT3, but did not think this would matter too much.
This has gotten worse by the day, and now I have a very frustrating clutch to operate... if it has not been used for a bit (60 seconds or so) the first push on the pedal feels very soggy, the clutch only half disengages, and the pedal sticks 1/4 to 1/2 way back up... Putting a toe under the pedal allows it to be pulled up, and as long as it is being used continuously it seems to work just fine... however as soon as it goes unused for a minute or so...
The clutch can be "pumped" up by bouncing on the pedal lightly before attempting to use it, making me think that it was still a fluid issue due to the incorrect fluid I had used so this afternoon I obtained some DOT3 and bled the whole system again... with little difference...
The problem seems to be much worse when hot than cold, and I am not losing any brake fluid... The slave also seems to retract correctly when the foot is taken off the clutch, even when the pedal does not return properly.
Now thinking that this must be either the pedal assembly (unlikely?) or the master cylinder... sigh...
Anyone got any ideas on this one?
Chris.