Mystical and difficult clutch problem

[dmj]

I just rebuilt my 911 SC engine and replaced the clutch to the 915 transmission at the same time.

Now, the engine is in the car but the clutch won't disengage. The pedal can be pushed to the floor, but it's very heavy to move it.

It feels like either there is too little force to disengage the new clutch, or the new clutch is stuck in some way.

I tried many things:

- Checking the pedal cluster and removing the floorbord for max pedal travel

- Adjusting the clutch cable in various ways

- Applying force to the rod under the tranny connected to the fork, using a bar. It only moves 5-10mm.

- Removing engine and checking that the rod is aligned with the throwout bearing, and it's ok

- Separated engine and tranny, checked fork and removed pressure plate to check throwout bearing, looks ok

- Omega spring is old and sas rusty, but looks ok. I made extra room to fit with my new SSIs

- Greased splines and inside of throwout bearing (clutch is all new kit from Sachs)

.. still the same problem. The pressure plate seems to be stuck in some way or just too hard to move.

Anything I'm missing here? I'm starting to loose faith after an allnighter as I had to pull and insert the engine again.

[Flat6pac]

Use a mirror and flashlight and check the left portal to see if the fingers are engaged into the throw out brg.
If you put the engine and trans together with the fingers behind the TOB you have distorted the release fork to 80mm from 75mm so you would need to change the fork.
Thoughts...
Bruce

[mreid]

You had to check the throw on the pressure plate in order to install the throw out bearing (must depress the pressure plate, hold the bearing in place, install spring washer, retainer, and locking ring). You would have noticed any issues with the pressure plate and throw out bearing during installation. That is how you installed the throw out bearing right?

[dmj]

Fingers are engaged.. The fork was working well before and it was correctly installed. I can't see the botton finger though and I heard a story where only one fibger was connected. The fork looks straight and ok though and I tried to re-install twice just in case.

I got some help to restore the longblock from a veteran porsche mechanic who did several hundreds of engines. He installed the clutch which was delivered as a complete kit to me with pressure plate and disc, but perhaps he made a mistake.

I removed the pressure plate and looked at the bearing. It can be pulled about 5mm out and it moves slightly around if you push it, perhaps 5mm. I assumed the bearing was already attached on the new plate in the kit, but perhaps not.

Could it be the throw adjustment? What is that and how do you adjust it? It feels like the bearing is ok and that the play in the rod/ clutch fork comes from pulling that 5-10mm, but the pressure plate seems to be stuck after that and the clutch doesn't disengage.

Thank you for the problem solving on this one!

[dmj]

Any more thoughts on this?