Can't say I've tweaked the clutch lever arm adjustment or throwout stop since 2003. I've always noticed the clutch grabs basically right off the floor. How can it be set to have a small amount of pedal travel before the clutch takes up off the floor? It did kinda feel like when I had reverse engaged yesterday and the clutch pedal in, the car had a slight feeling like it still wanted to move, as if the clutch was not 100% disengaged. I don't think I have the full .060 thou gap between the clutch lever arm and the head of the adjuster bolt with the lever arm pushed outwards taking up the free play.

What should I fiddle with first? Lever arm adjustment bolt or throwout stop?

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http://www.youtube.com/user/Hanras

Pull the arm out and check for wear first, I had the same problem as you and it turned out that all the pivot points were worn, so I bought all new bits and it is now like new. You could also try bleeding the slave cylinder.

Was the clutch peddle feel ok before you done the m/ cyl ?, may be a bleed issue .

I think the adjustment bolt is usually set @ 20 thou .

Have you done search on here Re: Clutch Adjustment ? , there's plenty of info .

I think its always felt this way since 2003. Clutch takes up straight off the floor. Its kind of hard to remember as its nearly been 3 years since I drove it. The workshop manual I have states .060 thou once the freeplay of the lever is taken up between the head of the bolt and lever arm. The slave cyl, bled up really well. Two man job. Pumped heaps of fluid through it.

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http://www.youtube.com/user/Hanras

Set the free play at 020 thou. The 060 was for early model 850's.

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1969 Cooper "S"
1967 Mini Deluxe
1973 Clubman Van (the fleet spare)
1978 ex 1275 LS ("Wizard" Eaton Supercharged)
2015 HSV GenF GTS(occasional drive & tow car)
2019 MINI F55 Cooper S

Righteo, cool thats something to try!

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http://www.youtube.com/user/Hanras

The new Lever Arms that are available from the various Mini shops, are they exactly the same as original? Are the dimensions the same at the top section where the clutch return spring bracket fits onto?

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http://www.youtube.com/user/Hanras

I bought one of these from Minispares UK, fitted properly and works great.
PRE VERTO CLUTCH LEVER ARM HEAVY DUTY P/N 22A2204MS, only cost A$17.00.
My old one was worn out and had a crack in the bottom bit where it goes into the carrier.
ANY wear at the release bearing end is multiplied by the time it gets to the slave cylinder,and there becomes a stage where the slave cylinder piston is at its full extention(hitting the circlip in the cylinder) before the clutch is disengaged properly. Adjusting the big nuts on the release carrier should be done after the initial setup is done,eg 020" clearance between the arm and adjuster bolt head , so that the release bearing isnt touching the diaphram when the clutch is relaxed.

Thanks for that Leon. Can you please confirm that end of the arm where the clutch return spring bracket is fitted is still the same dimensions etc as the original arm?

I bought a bracket from Minispares, but it was a lot wider at the base? Got me thinking these arms may in fact be wider also?

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http://www.youtube.com/user/Hanras

I've got one of the later arms on my car , and the original bracket fits it ok .

I just measured the new arm at the spot where the spring bracket stops at the lower end , and it is 0.7 inches wide. I havent got the original any more as it was scrap.
Minispares say that "2A3601MS this plate is on the end of the PRE A plus long type clutch arm 22A2204MS to hold the return spring 1G5999. The clevis pin to hold this on the arm is CLZ518--this is the square type but for earlier tapered type Rover arm see 2A3601. This plate is 20mm width both ends"

This was the issue with the bracket that I had

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http://www.youtube.com/user/Hanras

From memory the large end on the Mini Spares bracket was 23mm across and the smaller end was 18mm.

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http://www.youtube.com/user/Hanras

2A3601
CLUTCH RETURN SPRING ANCHOR FOR GENUINE CLUTCH ARM
This plate is on the end of the PRE A plus original long type clutch arm 22A2204 to hold the return spring 1G5999. The clevis pin to hold this on the arm is CLZ518.

If you have the later Mini Spares arm with 22A2204 stamped on side with a square end you require [link2A3601MS[/link].This plate is 20mm wide spring end and 25mm wide clevis pin fitting end.

See Minispares Website
http://www.minispares.com/shop/classic.aspx?c