I have a 94 Geo Tracker 8 valve 4X4 with a 5" suspension lift and 31x10.50. I just changed my clutch, disk, pressure plate, pilot bearing, throw-out bearing and turned the flywheel. No matter where I adjusted the cable, it was always too tight, so I replaced the cable, shifting was smooth and pedal had a nice light feel. This only lasted for 1 day, then it started getting stiffer and stiffer at the pedal to the point I thought the cable would snap. I also have no power on hills or against the wind (used to be much better) and my fuel economy has dropped so much that I only got 130 miles from a tank of fuel (possibly a seperate problem). I checked for cracks in the firewall, none detected, checked for broken welds on the pedal arm, nothing seen. I'm at a loss............. any ideas would be greatly appreciated!!

I would say change the clutch cable, but you already did that.  My clutch was very hard to push in too, but I changed the cable and it fixed it.   I've heard some cheaper cables may not last long.   So if changing the cable seemed to work last time, even for a few days then that might be the place to start.

Sounds like a bad clutch.  L have a buddy that had that problem in his toyota new clutch pedal got real hard he blew the seals out of 2 slave cylinders changed the clutch again  problem solved 

I dropped the tranny out again, clutch disc and plate look good, bearings are fine, although the throwout bearing seems to have a little (not much at all) "slop" on the shaft it rides on. Are these shafts replaceable? Could it be binding? Are there slave cylinders in a Tracker clutch? If so, where would I find them? Thanks for the info.

No slave cylinder on a 94 Tracker clutch - 99 and later have them.

The slave cylinder is a part of the hydraulic operating system that replaced the cable.

That's what I thought, thanks, but I'm not a mechanic so I wanted to be sure.

Did you use a re-manufactured clutch or a new one?  My buddy did a clutch and the re-man was too thick and he had similar issues.  Also,  get the suzuki clutch cable if you can.  I've had replacements from NAPA, Oreiley's, and Autozone last less than a week.

I used a new clutch kit, not a remanufactured one, but I did use a after-market clutch cable. We don't have a Suzuki dealer near here, would an OME cable from the GM dealer be the same as an OME one from Suzuki? Thanks.

I was aslo wondering, I have the 2 nut style cable, there is a 62" housing, and 66" housing, I was given the 62". Is there a real difference between the two? They are both the same overall length, just the casing is a different length.

There are index marks on the clutch pedal shaft  & the clutch pedal lever.  Are they in alignment?  You'll probably need a mirror to see them.

No power on hills, and poor mileage after changing a clutch?  Is the clutch slipping?  Did you install the clutch with the springs on the transmission/pressure plate side?  Does your motor RPM's increase easily when you are taking off, or on hills?
The throwout bearing should have a little slop on the transmission jack shaft.  Is the throwout bearing engaged on the dogs of the throwout fork, or is it just sitting in front of the throwout fork?

The clutch doesn't seem to be slipping, and the RPM's don't change (other than going down as it slows down). The slot on the throwout bearing has the peg through it and is resting against the fork, if that's what you mean by "engaged"? Couldn't tell you for sure about the spring side, it was labelled "this side to flywheel", so that's what I did. I think the lack of power isn't to do with the clutch, it smells like it's burning really rich, I think it's just a coincidence that I noticed it right now. I'm thinking it's the aftermarket cable, the clutch was smooth as silk for a day or so after I changed the cable, I just didn't think it could go that quickly. I'm going to get a OME cable and try that, thanks for the tips and thoughts!!

I put a proper 66" cable on it, problem seems solved...........................for now!! Now I just have to figure out the bad idle/gas mileage no power issue!! Thanks for all the input.