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I'm reinstalling my engine after a rebuild and can't get the release collar to go in all the way to lock. I've pulled the engine back out twice last night looking for something out of place and can't find anything. The collar locks in nice a tight to the pressure plate when the clutch is off the car and the collar/fork assemble is off the transmission, but when reinstalling like normal I have about a 1/4" gap left I need to close as seen in the pictures. I've tried using a pry bar and a long screwdriver to force it in more, but neither did anything.
So what are my option besides pulling the engine again and buying new parts hoping it fixes the issue or trying to remove the bolts, get the collar to grab, and then reinstalling using the lower access hole? This is as close as i can get. Fork held by 550 cord.
Typically the throwout bearing doesn't stay totally flush, it does come back a little bit after it's locked in. You do need to use a pry bar or something to pop that release bearing into the collar. Push the release bearing all the way forward.
Also the round sleeve the release bearing rides on has surface rust on it, that really should be nice and smooth and lubricated with a light coat of grease. Long term that can cause binding or weirdness. You can probably get some grease up in there with the trans in. If the trans was off the car, I'd take a scotchbrite pad and some WD-40 to that surface then lightly grease up with wheel bearing grease.
If i recall correctly, the throw out bearing is locked in place when the retaining clip is spaced out away from the pressure plate. Better experts can chime in, but I believe to lock the throw out bearing in place you can just press the clutch pedal in fully and it will seat the locking ring. Then just make sure the locking ring retracts with the throw out bearing while the clutch pedal is released.
You have to use a pry bar to seat it initially. If you push the clutch down you'll eject the front of the slave cylinder into the transmission and dump out all the clutch fluid.
I can’t link to it but there’s still a video of how the pull-clutch works in the FAQ sticky at the top of this section. Just scroll down to ‘C’ for clutch. Might help you understand it better. The “slop” or play is visible in that vid
The gap you have is correct. The throw out bearing doesn't sit completely flush on the pressure plate. Once you engaged it in collar and heard the click, it should have sprung backwards a little bit.
