I have a '91 DX hatch, totally stock. Ever since I bought it, about 2.5 years ago, it has had a really stiff clutch pedal. At first I thought it may have a high performance clutch in it, but I replaced with a Daikin stock clutch about a year and a half ago, and I still have the problems.

Basically, I have to have the cable adjusted to almost the maximum tightness. In other words, almost all of the threads on the adjuster are above the plastic adjuster nut. This makes the pedal hard to push, and I feels like I'm putting a ton of stress on the cable. But if I loosen the cable at all, the clutch doesn't fully disengage, and the shifter won't want to go into gear.

A few months ago, my clutch pedal bracket broke. I removed it and welded the hell out of it. At first after I did that, the clutch seemed to be a little easier to push. But a month or two later, the cable broke. It broke at the bracket that hangs over the top of the clutch pedal. So, I replaced the cable, and now I'm back to where I started, with a super stiff pedal.

I could try just replacing the pedal assembly, but I want to make sure it isn't anything else first.

Any ideas?

 

You are not alone, I got sick of the stiff pedal so I replaced everything.
new pedal
new cable
new reinforced welded pedal assembly
new cable stay on the trans
new arm on the trans
new throw out fork
Car is still apart so, well see if there is any diff b/c I am using a Compclutch stage 4 setup

 

make sure the cable doesnt have any kinks and has large arcs where it needs to bend.