Sooo... no one knows if the cables have adjustments? I don't have my Haynes manual handy.

 

Not sure about the LS /LT manual transmission, I’ll search for information and post it later today

 

I drove a standard trans pickup truck in DC traffic (the worst traffic in the US according to published reports) for many years as a job, upwards of 50,000 miles per year. Never wore a clutch out. Before that I used a VW for the same job never wore a clutch out. I would bet I shifted gears more in a month than you do in a year.
If you ride the pedal in anticipation of shifting or stopping you are killing the clutch.
Did I indicate that you said anything about topping off the brake fluid? But, If you don't, why would you think the fluid had been replaced "by now"? You didn't mention flushing it.
Why did the clutch wear out so quickly? Even 160.000 is low mileage. You did not mention a previous owner, that could be blamed.
You did not mention that you were a professional with many years of experience working on and operating a HHR. Sorry if I was supposed to know.
The shift cables on the Getrag trans does not seem to have an adjuster. There is a Neutral lock on the shifter. The MU3 has an adjustment in the shifter and the lock is on 4th gear.
You are very welcome for the help.

 

I replaced the shifter on my 2006 LT 5-speed a few years ago and I'm almost 100% sure there is an adjustment for each cable.

Steve

 

The KY clutch I got from TTR only lasted a year, maybe less. It was the first time I worked on a clutch, so not sure if I did something wrong installing it, or if it was just junk.

 

I have done a bunch of clutch replacements.

There isn't much that you could do wrong if everything went back together. Most issues would be related to the design or materials of the clutch disk or pressure plate.

Did it wear out that fast?

Did you replace or resurface the flywheel?

Steve

 

Resurfaced. And towed to the shop for fluid fill and bleed. It started chattering just a bit shortly after install, maybe a couple months.

Yeah, my mechanic said everything was trashed in there.

 

My guess is a bad part caused the problem (section of clutch came off backer, pressure plate finger broke, etc). Like I said, not much you could do wrong unless something unscrewed.

Steve