C2 Clutch Release Problem - Still

[George C.]

Continuing from my previous post, the clutch will not release. I have taken the car all apart and had the rebuild shop verify that the pressure plate is set up correctly. I took a measure as I was reinstalling; with the clutch bolts just tight enough to hold the disc in place I had 1.5 inches when I measured from the clutch face to the inside edge of the diaphragm fingers. When fully tightened down I still had 1 inch of distance does that seems like it should be sufficient for the clutch to release? I know the disc and the trowout bearing are installed correctly, yet I still have four inches of free pedal with the threaded clutch pedal rod adlusted all the way to the end. I think the problem is that the flywheel has been cut to much, and am looking for others to confirm. When all linkage is hooked up the clutch fork is beyond 1/2 way through its travel, this is seen when looking at the position of the fork as it exits the bellhousing. Also the shoulder cut in the flywheel just allows enough room to tighten the clutch bolts down. Can anyone give me an idea how think the flywheel shoul measure. The other possibility is that the clutch fork pivot ball is incorrect, but this clutch did work fine before I decided to "rebuild it while I had the transmission out". Can some one tell me the correct length for the ball stud? I have checked archives and think I am on the right track, but have not been able to fully answer these questions.

Thank you all in advance for your continued assistance,

George

#36908

[Mike McKown]

Re: C2 Clutch Release Problem - Still

George:

Your flywheel was probably cut .010/.015. I would think that would be the amount of clutch travel attributable to the resurfacing of the flywheel.

If I were working on your problem, I would assemble the pressure plate and disc to the flywheel and secure the pressure plate to the correct torque then measure from the flywheel clutch surface to the top of the pressure plate release fingers. Compare that dimension to a known good clutch or a known design dimension.

If the replacement disc is just a little too thick, and I can't tell you how much, it will drop your diaphragm fingers away from your release bearing by a large amount. That's why I would tighten the assembly to do the measuring.

If you have four extra inches of travel it almost sounds like you have a straight finger diapragham with a bent finger throw out bearing. Either that or your arm is not on the ball stud.

[Timothy B.]

Re: C2 Clutch Release Problem - Still

George,

Can it be possible that someone has changed your clutch linkage bellcrank, I know some are different?

[Mike McKown]

I just read your first post,

and then I re-read your second. I don't understand about the "shoulder" they cut on the flywheel. Did they not resurface the whole face? It sounds like maybe they cut only the disc wear surface and left the pressure plate mounting surface alone. Even at that, this would give you a weak pressure and less free play, not more. I think Joe Ray and Wayne put you on the right track in your first post.

[Thomas R.]

Re: I just read your first post,

Did you get another Pressure plate or are you still reusing the one he gave you. I had the exact same issue as you and until the vendor gave me a new Pressure plate, I was stuck like you. Also, is there any play where clutch fork pushrod and the pins. 1/4 inch play will make make at least 1 1/5 inch travel in clutch pedal, hard to believe until you see it.

[George C.]

Re: I just read your first post,

The pressure plate is the one that was in the car and working before I started this.

Sorry I wasn't clear when I said the shoulder. I was referring to the holes in the flywheel for the pressure plate bolts. Anyway I have ordered a new flywheel and I think that will turn out to be the culprit. I really have no way of knowing how many times this flywheel has been resufaced, and can't find a measurement for the thickness of it.

George