I put in the 10 lb fly, 6 puck and rear main, new coolant plug, New TOB and pilot, input shaft seal, rear transmission seal, cas seal Might as well while you have it all off trust me it sucks taking it all right back off :giggle:

Call me crazy, but it looks like the clutch disc is too big and will hit the inside of the pressure plate wall from the pictures shown.

On a 1.8, a six puck does not go all the way to the outside diameter as shown on your 1.6. I don't have a 1.6 setup around to compare or I would check it.

Anybody?

it does look a bit on the large side, but it is hard to imagine that he would get the correct plate and not the right disc

I just went out and measured a 1.6 flywheel I have sitting in my shed, looks like the mating surface is 8" across (or more, looks like i didnt center the tape well). I think you should get in touch with someone who can measure these parts for you so that you can verify weather or not you have the right parts.

Looks big to me too. My disk has about a 1/8'' gap all the way around when layed on the PP and flywheel. That one seems to hang off the sides.

Well I know I ordered a 1.6 disc from ACT direct and the pp was purchased from someone on here with a 1.6? and when I measure the pp its a little bit over 7 3/4" and the disc is slightly under and the flywheel is right at 8", also I didn't have them lined up exactly when I took that one picture? But I dunno it seems like the disc lays perfectly on the PP:hustler:

well i took it off again and the disc definitely measures 7 3/4" and PP 7 7/8" and flywheel right at 8

But I cant really figure out how to torque the bolts correctly It takes more than 27 ft lbs to pull the PP to the flywheel? :hustler:

Only thing I could think of is the PP frozen up or in a bind. Ive never seen a faulty PP in that respect, but thats the only thing I can think of that wouldnt let the PP pull up tight to the flywheel. Maybe force the fingers on the PP down and tighten the bolts? But again, Ive never heard of this before, so I dont know. Strange problem, Im curious to see what it ends up being.

Try putting the PP on without the disk. See if it goes on flat then.

I can tighten it down flat but It takes a 1/2" ratchet?

Do the bolts thread smoothly into the flywheel holes? This is puzzling. Maybe its a manufacturing flaw, holes may be out of alignment or something. Any little thing could cause a big pain in the ass.

I can turn them in by hand smoothly then turn them with a ratchet easily til their is a gap like the first set of pics I posted, then It takes a bit of effort to pull the PP against the flywheel, but I fixed the clutch fork and I'm just gonna tighten the bolts back up as best as possible and see what happens :eek5:

Maybe thepp cover got bent a little and when you torque it some your putting it back in shape. I think if you find you have a little free movement in the front of the fork to the housing youll be okay

OK, I'm going out on a limb here, but are you sure you're using the right bolts to mount the pressure plate to the flywheel? If the bolts are too long, they will bottom out, and not tighten pressure plate down. Looks to me like, the disc might be installed backwards. Can you take a picture of the disc from the top looking down, the slimest view, viewed like it would be installed and you were looking up from the ground at it? Not sure if that is the best description.

Im using the stock pressure plate bolts and loc-tite the non permanent kind, and the disc has a sticker for the flywheel side so Im sure I have it right this time

Please don't do that. It would suck if that sucker broke loose and came through the tranny tunnel. Something is definitely off there. I second the too-long PP bolt gig. Measure the hole depth and check. threads buggered?

ps dude, you got nice pink/red grease on your carpet in that pic. Your old lady is gonna kick your ass.

Its the old pressure plate bolts? and same flywheel so I dont see why that would be wrong and I have a badass carpet cleaner :eek5:

If you put the PP on the flywheel without the disc, and you use OEM bolts, and it's still rough, the only thing that it's contacting are the dowel pins. Are any of them bent? It could be the photo, but one of them looks tweaked in one of your photos.

Please make sure you take video of this fail.

UPDATE: Well I found out the threads on the flywheel were damaged first off... and the factory clutch flywheel bolts were to long for the new PP and lightweight flywheel, and the shift fork pivot wasnt 100% on so all those together :bowrofl: its all put back together and it went back together like it should :eek5:, but now my ? is do I have to line up the starter any special way??? :hustler: