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clutch

To: les_burkholder@sunshine.net
Subject: clutch
From: bristol@coastnet.com (Jim Walters)
Date: Tue, 1 Jul 1997 10:30:05 -0700 (PDT)
Hi Les, I can almost guarantee that you have a broken finger on the
pressure plate. If you remember when you put it together you would 
have seen about 15 fingers in the centre pointing towards one another
which the throwout bearing rides on. These fingers are the spring in 
the pressure plate, if the spring breaks or collapses one finger will
stick up farther than the others pushing the throwout bearing way
back and uses up all of the pedal travel. This is especially likely
if you put in a rebuilt pressure plate instead of a new one, but 
even a new one can collapse after a short time. There is one other
possibility and that is too much end play on the crankshaft, so much
so that the thrust washers have fallen out and the crank is moving
ahead as much as 1/4 on an inch also using up all of the pedal travel,
however I feel that this is unlikely in your situation. The throwout
bearing arms on Ford transmissions will sometimes crack and bend causing
the same symptoms, however you have said that the bearing appears to
be moving a considerable distance. If you can see into the bellhousing
you may be able to see one finger a little proud of the others, however
it will not usually be readily apparent until the pp is unbolted from
the flywheel and the pressure released. The previous is assuming that
you are sure that ALL air is out of the system.Good luck. Jim


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