Odd Clutch Problem

[ehanson]

I have a 68 2000 which has been idle for quite some time. Engine and trans were out years ago, and both rebuilt, but never fired. All looked OK, but once fired, I found the clutch would not disengage. Looking through the clutch lever hole, all looked normal, but figured I maybe somehow managed to install he clutch disc backwards. Pulled engine new disc in hand, but turns out, I did not mis-install it. New disc in anyway since I was there.

At the time it was out, checked the bearing sleeve and TO Bearing, against my 2000 doner, and it matches. Clutch cover height, matches doner. Tip of pivot to bellhousing face, matches. TO Arm matches, and is un damaged. Engine Backing plate matches. Flywheel thickness matches. Roller Pilot Bearing is smooth, verified using spare input shaft. Trans spins freely in and out of gear.

When Clutch should be disengaged via pedal, I can adjust it out far enough that the back side of the arm nearly touches the back side of the TO Arm hole, so it is completely out of throw.

What the hell am I missing here?

[C.Costine]

Under high humidity storage conditions a clutch disc can rust to the flywheel. Any rust pattern there?

[ehanson]

Clean as a whistle.

[theunz]

Throw out bearing on backwards?

[ehanson]

Nope, same as doner.

[dbrick]

Just a couple of thoughts. My first thought is the clutch cover is NG, as everything else is a pretty simple lever or pivot and all seem correctly located. Clutch cover has a whole bunch of possible, even though unlikely, failure points. Was it a new cover?
Does the TO brg contact the clutch levers in what seems like a normal position, and is there a normal amount of resistance as you move it?

[theunz]

Is the engine back in the car?

[ehanson]

Hope the cover isn't the issue, but could be. In theory, it is a 600KG Daikin from back in the day, balanced to the flywheel when the rest of the rotating parts were balanced. I will pull the 2 covers, and measure the finger height. Maybe something weird there. It is still out of the car. Would be huge help to know the measurement from the front of the TO Arm to the front of the TO Arm opening on one that is correct.

Thanks in Advance

[cktrap]

Just went through this the pressure plate is the wrong. It's not tall enough to reach the throwout bearing. That's my guess
Keith

[ehanson]

Found the answer, and maybe it will save someone some grief down the road. After lots of measuring, and checking, it turned out that the Roller Pilot Bearing that had been driven into the crank long ago, was about .001 shy of where it needed to be, and the outer piece of the race was binding on the chamfered portion of the input shaft. Found it by bolting the trans to the engine with the clutch out. The trans slid home with no issues, but when the bolts were fully tightened, it was touching just enough. Backing the bolt off just far enough to uncrush the lock washers allowed the input shaft to turn when in gear, and left a small mark on the input shaft. One light tap on the bearing, and problem solved.

[Nissanman]

Don't you hate that
Well at least you know next time