I swapped in a KA and a 5 speed in my 89 240 and I've been through a lot with this little project but it's still not done. There seems to be a delay when I let go of the clutch. When I let go the engine revs and the car goes forward just fine, it just doesn't have the normal feel of engagement. I can't spin the tires in 1st at all. Any ideas?

 

did you use the stupid little damper box?
if you did then remove it

if not just go under the dash, pull the cotter pin on your clutch lever.
take the rod that goes to your slave master, and adjust it.
you can screw and unscrew it.
off head i cant think of what way you'd want to go...
\but that's what i did.
gave my pedel ratio more feel and more clamp.
i think i unscrewed mine.
my pedal releases up towards the top but clamps hard

 

Is the damper box the one with the line that goes back and curves back in? Also should I screw the adjustment fork toward the fire wall or toward the drivers seat?

 

www.takamotorsports.com

go there and get their stainless steel clutch damper removal line. I got one for when I did the auto->manual swap on my 98 240, and compared to my friends 5 spd 97, my clutch feel is much stiffer and nicer. definitely worth the $45 shipped.

 

As it turns out I was playing with the adjustment stuff so much that at one point I got it perfect and thought the problem was fixed. I left the MC bolts kind of loose so I could adjust it more after I drove it but that was a mistake. I drove it for 2 days and I lost more and more clutch to the point where it wasn't grabbing hardly at all and the clutch was getting magma hot. What I couldn't understand was why the problem was getting worse. The bolts were getting less and less tight every time I put in the clutch. Damn I'm stupid!!! When I checked the bolts they were finger loose. I made a last adjustment, tightened the bolts and now the problems fixed.