Hi guys.

im stumped on this problem i have, i got a TF magna 3.0l, had a manual conversion done last month, new PBR clutch kit (for 90% grandpa driving) rekitted master and slave cylinder, new seals. now the problen is, every morning i get in the car, the clutch free play is about an inch, inch and a half, after a good run and i get everything all nice and hot, the free play is gone. so last week i adjust the clutch pedal hight and free play to the workshop manual spec, also bleed the lines again to be sure. and i still get the same problem each morning. any ideas are welcome

P.S the conversion was done by a mechanic

There is a pressure relief port in the master cylinder that is supposed to release all pressure in the hydraulics when the pedal is up. If it is blocked or not uncovered through insufficient pedal free play, it can accumulate pressure and do what yours is doing (I'm assuming the clutch takeup point varies too when the free play disappears). Might need to recheck the rekitted master cylinder to make sure the port is clear and the rubbers are sitting right.

Perhaps increase the cold free play a bit and see if that helps? Should help tell you if that is the problem area.

MadMax.

yeah thats what i did when i readjusted the clutch hight and free play to specs, it was of a morning before i started the car, everything was cold, and never pumped the clutch, i took up all the free play, everything felt good, the clutch felt nice and tight, then next morning, it was back to the same thing, had all that free play again, and felt spongy. i may have to recheck the master cylinder again, or just get a whole new master cylinder

. . . i took up all the free play . . . .

Should have SOME free play!

Maybe the master cylinder is retaining pressure when you use it, but leaks down overnight and allows air in?

I'd be checking the master cylinder for scores, dirt trapped under the new rubbers (the tiniest speck will do it) and see if the new rubbers are doing the right thing - no score lines in the lip, lip not bent over. Followed by a thorough bleed.

Worth checking over, as a new one isn't cheap.

yeah, free play is 6-13 mm, found out the person who did the rekit didnt replace the small valve spring? he reused the old spring because it was larger then the supplied one in the kit, so im assuming now thats where the problem is, going to rekit the cylinder myself now. in mackay if you want a job done properly, you have to do it yourself, or take the car to townsville lol