Clattery when cold
Join Date: Feb 2012
Location: United Kingdom
County: Greater London
If it's stopping just an inch short it sounds like the input shaft is going through the splines on the plate OK, so either it's baulking on the flywheel centre hole or the release bearing and fork are misaligning somehow.
I did once have a cheap universal clutch tool that had different sized collars for the flywheel and different collars for the plate. It wasn't much good at aligning the plate centrally as the various bits had some slop and it drooped under the weight of the friction plate. That was enough for the input shaft to not nose into the flywheel, preventing the bellhousing sliding home. So I hope you don't have one of those, it caused me plenty of trouble until I realised what was going on. Easy enough to check, just stick the tool back in the clutch and make sure it sticks straight out at 90deg. It has to be spot on, a misalignment of even a couple of mm will make life difficult.
EDIT: It also occurs to me to ask whether you're sure you put the friction plate in the right way round? Usually they ain't symmetric and one side sticks out and the other does not.
Last edited by halftone; 19-02-16 at 01:00.