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Ever since my clutch master cylinder was replaced (clutch internals, excepting the slave cylinder, have about 60k on them), I too have had the free play you describe. It really bothered me, as this play was not present until just before and then ever after replacing the master cylinder. At one point it got really bad, which is when the slave cylinder was replaced (even though this was new when the clutch was done), and the master cylinder was replaced again, in addition to the clutch pedal itself, and the hoses. This all was just over a year ago. Since then, play has decreased _slightly_, but it's still there. I just got used to it I guess, but to this day I still find it odd that it had essentially no play until the master/slave went out, and now with everything except the disc/plate replaced, still has the play..
As for taking the car out of gear without using the clutch, this shouldn't hurt anything, so long as you are coasting when you take it out of gear, and preferably, the lower the RPM the better, I think. Many people have done this in the case of a clutch failure, in an emergency, but if done right, I can't think of anything that wears more than it normally would.
Someone correct me if I am wrong, but the synchros are only used when putting the transmission into gear, not when shifting to neutral. Right? Still, I found at least two cars which differ greatly in how easy they are to get out of gear. My Dad's '85 Honda seemed quite happy to shift without the clutch, just matching revs. You could pull it out of any gear no problem. On the 9000 however, the lever seems much more reluctant to move out of gear if not using the clutch.. But, I should admit I've done very very little 'practicing' on the 9000, for fear of screwing something up. The transmission on Dad's car was on it's way out at 265k...still shifted great though!
Aaron Gilbert
1987 9000T 253k miles
, Wed, 14 Mar 2001 15:15:51
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