My conclusions would be (please let me know if any of you disagree):
1. The rod in the slave does not affect the clutch free play, it only affects where the piston in the slave is. Unless of course the piston bottomed out when pedal is pushed, in that case adjusting the rod would have an effect. The rod (middle of eye to other end) should be 3,07-3,09"
2. The proper way to adjust is to remove return spring, have engine running, use hands to move arm until bearing is felt to touch pressure plate fingers. At that exact point the distance to the return stop bolt should be 0,102-0,106". Adjust stop bolt. Install spring again.
If 1. and 2. are true, that means that
a. TSB 10 page 9 instruction on how to adjust stop bolt is grossly misleading
b. When clutch is at rest, the arm should also rest against the stop bolt. When I bought the car, the previous owner had adjusted so there's a 0,1" gap at rest. I can't really blame him, that's what I would do if I had only TSB 10 and not this great Forum
. Maybe that's why my slave cylinder failed, nothing but the piston to take the beating when the clutch pedal is released fast?I hope this is right, I can't afford another clutch, or worse wearing down my syncros...