Posted by Gordon Maney on Monday, July 14, 2003 at 1:42PM :
In Reply to: Grumble... (clutch....) posted by Josh Schroeder on Monday, July 14, 2003 at 10:45AM :
You don't tell us what kind of truck you have, 1-ton Power Wagon, W-series, etc. but let's consider your question.
Have a helper step on the clutch pedal, have the transmission in top gear, and try to turn the drive shaft or output shaft of the transmission with your hands. See what you get there....
No matter whether it is a hydraulically actuated or mechanically actuated clutch, you should be able to disconnect the throwout lever from whatever causes it to move. At that point, you should be able to move that lever forward and backward, even if just a little bit, so we can know that it is not applying force on the throwout bearing. That motion amounts to the free travel you need to have present in any clutch installation.
If you don't have any possibility of free travel, then we have to disassemble the truck enough to find out why.
There is a lot I don't know about your situation, but my first guess is that the disc is in backward, meaning the incorrect side of the clutch disc is toward the flywheel. The assembly in the center with the coil springs.... that is a torsional dampening assembly; it is offset from the centerline of the disc. If you have it offset toward the flywheel, it will, in many applications, rub against the flywheel and act as if it is not disengaging fully, which in fact would be the case.
In that is true, you will have to remove the transmission and pressure plate in order to turn the disc around.
Maybe I am missing something, but that is my thought based upon what you have shared.