The clutch pedal is starting to feel pretty rough when I let out on it...kind of notchy, not smooth like it should be. Is there anything I can do (easily) to smooth it back out??

Thanks!

 

To me that sounds like the throwout bearing binding on the input shaft. At 155,000 (on original clutch), my old Saab 900 needed to have that lubed up. On the Saab, there is an inspection cover through which I was able to squirt some spray grease through a "straw," and get it fixed. On the 1 gen 6 speed, you are likely going to have to pull the transmission if that's it. There is a metal dust cover on the bellhousing to block mating area right next to the inside passenger side CV cup that you might be able to snake up some lube through.

 

Given some further thought, it would only take a minute to flush out and lube the pivot area of the actuator fork where it goes into the transmission housing. I'm not really sure if that would bind up, or what kind of success you will have dealing with that externally, but it can't hurt. I'd spray some PB blaster at the pivot point, and follow with compressed air. Then use some spray grease such as Einszett ultra gel. Work it through by stepping on the pedal a few dozen times. Wipe off excess, and don't forget to put the belly pan back on, to help keep road crud out of that area.

 

Is spraying a bunch of oil and/or grease up in there a good idea? Isn't there a pretty good chance that I could get some oil on the flywheel and/or clutch pads?

 

Spraying the outside of the fork, negligible to none. As for the input shaft, yes. With the Saab I was able to use the red plastic straw to direct the lubricant directly onto the sliding area. By using minimal pressure on the aresol, none got anywhere it wasn't supposed to. This type of grease comes out like a penetrating oil, finding it's way into where it needs to be. Within seconds after contact with air, it solidifies into a grease. Similar to some motorcycle chain lubes. Now that was the Saab I owned. The plate I mentioned on the R53 trans is below the starter, and even with the INSIDE of the flywheel. So even if you could see the input shaft at that angle, you would have to use some gooseneck type of deal to apply the lube where you want it. Maybe form a permanant angle on one of those straws (although the ones that come with the can aren't long enough) by using heat, and bending. You are going to need to remove the RHS halfshaft to get in there (and drain trans).

Let me clearly state that I'm no mechanic, and my diagnosis is purely a guess based on my personal experience. I'm wondering if a bad clutch master or slave cylinder might also give a rough operation. That would be awesome, because those are easy (and cheap) fixes. I'm making an assumption that you feel the symptom even with the engine off.

 

Actually, lubing the sliding area of the throwout bearing is probably not needed on this application, since it's a plastic bearing. Hence no suitable access port for doing so.

 

Well, maybe it's just the pivot point on the transmission. I'll have to get under there and see if I can lube something. Thanks!