MG Car Repair: MG Midget Clutch, clutch system, clutch pedal

Question
Hi Howard.  My question concerns a 1976 MG Midget, which I bought as a non-runner 4 months ago, knowing it had perished hydraulics from sitting 3 years.

I replaced the clutch master and slave cylinders and bled the system per the Haynes manual, but have a lot of pedal travel before encountering resistance. The previous owner had apparently encountered the same problem, because he had notched the slave cylinder to allow it to be pushed further into the bell housing.  The slave rod is the correct length (the longest made) and does not have any unusual play, and the clevis at the master cylinder fits nice and tight.  The gears grind when I attempt to engage with the clutch pedal fully depressed and the idle speed at 800 RPM, so apparently the clutch does not disengage.

I think I've done a decent job of bleeding the air out, but understand that this can be a problem on the Midget.  Is there any way to verify that all the air is out, before I take on the job of pulling the engine and tranny to see what's up with the clutch?

By the way, it would not surprise me that the clutch could be worn or even that the lever could have been installed back to front, by the previous owner.  He had installed the weather stripping inside out, so nothing would surprise me.  I just want to be sure I haven't overlooked the simple before taking on the difficult.  

Thanks,

Brent

Answer
Hi Brent,
It is difficult to get all of the air out of a clutch system but there is a test. First push the clutch pedal down by hand. The pedal should have about one inch free play then be firm to push and feel about the same all the way to the floor. If it is soft at first after the free play then it is possible that there is still air in the system. Look at the bleeder valve on the slave cylinder and confirm that it is higher then the line fitting. (Some slave cylinders can be installed wrong) If the bleeder is on the bottom it makes it difficult to get all of the air out.
The clutch arm can not be installed backwards. However, if the car has been sitting for a long time the clutch disk can be stuck to the flywheel or pressure plate. This will not affect the feel of the clutch pedal but will make the clutch not release.

Sometimes you can bleed a clutch by removing the reservoir cap and open the bleeder with a pan or jar under it and let the fluid drain until you see the fluid is half way down in the reservoir. Don't let the level get too low or air will enter the master cylinder.

Howard