[jcain]

Well I've had the transmission on and off the engine about 4 times.

I have devised a method to help do this. I had some mild steel round bar and I cut it to about 16 inches in length. I then threaded one end at 12mm with a 1.75 pitch. I then screwed three of these rods into the bolt holes where the transmission mounts to the engine. The bolt holes I used were the left bottom and the one right above it also on the left side of the transmission and then from the backside of the engine on the lower right hand side.

With these guides in place you can quickly move the transmission out enough where you can access the clutch release bearing (throwout bearing) and pressure plate.

I confirmed that the clutch release bearing is properly installed. I also examined the clutch release shaft, specifically the pin that locates the arm to the shaft. This pin is very stout and straight, so this can be discounted as a possible problem. I had previously examined the bolt that holds the clutch release fork. It too is straight, tight and without issue.

One thing that I did notice. When the pressure plate is bolted into place that the actuator fingers are about 3/4 of and inch below the outside of the pressure plate. I don't know if that is acceptable or not.

I have come to the conclusion that the problem with the excessive freeplay is that there is too much distance from the clutch release bearing to the actuator fingers on the pressure plate.

The replacement disc and pressure plate are manufactured by SPEC, which is a reputable manufacturer. That of course doesn't mean that one of their employees might have mismatched the disc and pressure plate.

My next stop is to ask SPEC how much deflection in the pressure plate fingers is normal when the pressure plate is bolted to the flywheel and also to check and see if this disc and pressure plate is correct.