It’s difficult to say what is the actual cause of your problem is, but it sounds to me like something hasn’t gone back quite as it should?
I can give you an idea of some of the things that have gone wrong for me (speaking from bitter experience) during clutch reassembly (which may or may not help you isolate your problem)…
1) Did you get the anti-judder spring round the right way? One side has “outside” marked on it, which should face you when you look at it.
2) One friction plate has a larger internal diameter than all the others (easily overlooked). This one must go in first.
There are actually three types of friction plate in the clutch pack: 4x Type 1 (notched tabs), 3x Type 2 (colour coded) and the Type 3 (the one with the larger internal diameter). They must be fitted in the correct sequence and be soaked in engine oil first. The sequence is (from first in to last in with a plain plate between each): T3|T1|T1|T2|T2|T1|T1. The T1 plates notched tabs should fit into the right hand one of the two slots marked with triangles (the clutch housing should be rotated to get these slots at the top before you start).
3) If there are gaps between the plates after reassembly it could be that the pressure plate wasn’t located properly in the castellations on the housing. Also make sure the clutch spring bolts were tightened a little at a time in a diagonal sequence and then torqued correctly.
4) When you put the clutch cover back on the release arm will move. It is crucial you get this in exactly the right position to allow for this movement when you push the cover home. If the release arm is in the correct position (before you connect the cable), you should be able to push it forward (until it won’t go any further) to align with the two punch marks (one on the arm and one on the cover). If these do not align when pushed fully forward you will not be able to get the clutch adjusted properly. So take the cover off and rotate the release arm a bit further round and try again until you get it right.
Hope this is of some use to you…
Last edited by Pleiades; 17-06-13 at 20:48. Reason: plane/plain homophone confusion!
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