Clutch won't disengage on 4age KE70.

[gjgnz]

I purchased a Clutch Industries RPM361NSSC clutch kit several years ago and I've only recently fitted it to my project car (4age Blacktop engine and T40 gearbox in KE70 Corolla). Everything bolts up fine but it seems as though the clutch plate and clutch cover are not compatible. When I tighten the clutch cover bolts it compresses the metal fingers a long way, almost as if the clutch plate is too thick for the cover?

Pushing the clutch pedal with the motor running does not disengage the clutch enough to put the car into gear but I can start it in gear with my foot on the clutch. Releasing the clutch pedal with the handbrake on will stall the engine as usual. After pulling everything apart again you can see contact marks on the springs in the clutch plate centre where they have made contact with the metal fingers of the cover.

Any idea what might be causing this issue?

[Matt]

What travel are you getting on the slave cyclinder (how far is the clutch fork moving) ?

Video / pics would help with this post allot.

[gjgnz]

The clutch fork seems to be moving the right amount and the pedal feels fine. I initially thought there might be an issue with the master/slave bore sizes or fork pivot position but the fact that the fingers of the clutch cover are making contact with the clutch plate suggests that it's moving the right distance, just from the wrong starting position. Won't be able to get pics for another week or so unfortunately.

[Jimmee1990]

What are the part numbers on the clutch plate and cover you got? As they make the kits up to order it's possible one component might not be right.

Otherwise is the clutch pedal adjusted properly?

[phoenix]

You haven't installed the clutch plate the wrong way round?