Aaargh! New 915 clutch install with stiff throwout bearing / lever

[J-T]

Morning all - some advice please… to my shame I have been a bit of a lurker but now have a total impasse after 4 years of hard work on a very challenging but nearly complete restoration of a 1970 2.2T Targa. I have installed new sachs clutch full kit, new flywheel, 6-hole washer, yield bolts, pilot bearing… torqued & lubed correctly. Throwout fork correctly seated in throwout bearing. Everything aligned with alignment tool. Guide tube in good condition. Clutch fork not bent.

Have mated and unmated engine and gearbox twice, dismantled, reassembled, correctly (there’s an excellent Pelican Parts article on this)…. But lever will still not budge when clutch fork is in the bearing and mated. I know it’s a pull lever mechanism… not a push… Should it be completely immovable until the clutch cable takes some strain or is there something else?

I’m pretty strong so don’t think that’s the issue: it’s a 1970 2.2 with an early 915 (push fit from inside guide tube)… which I know is not a stock arrangement, but this should work. It’s the correct 72-86 915 clutch kit…





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[911hillclimber]

You will never be able to deflect the clutch arm on the box by hand (the one external on the splined shaft).

I would say you have done it all correctly and need to re-install correctly, esp the fork in the bearing groove, fit the cable, adjust and try it sitting in the car.

Will feel quite heavy compared to a normal car so don't be concerned by the pedal action.

[J-T]

You will never be able to deflect the clutch arm on the box by hand (the one external on the splined shaft).

I would say you have done it all correctly and need to re-install correctly, esp the fork in the bearing groove, fit the cable, adjust and try it sitting in the car.

Will feel quite heavy compared to a normal car so don't be concerned by the pedal action.

This is exactly the answer I was hoping for. Thank you!


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