I am not familiar with the diff. between the 216 and 235. I do know that it does not take much additional throw to make a cluch disengauge or not. Temp. adjust the rod with no play and see it it make a difference... do not leave it that way or the T/O won't last long.
I had some floor pans installed on mine incorrectly and did not allow the pedal to travel far enough... took along time to find. I pulled the trany many frustating times. The solution was to remove the rubber bumper at the top of the pedal travel for now...which provided more throw and waalaa.
I would try these things before you pull the tranny again. Verify more travel will not make the clutch disengauge 1st.... then figure why you need more travel or where you are loosing travel.
Clyde
