Any one have trouble w/ KEP pressure plates?, Mine won't release all the way??? Options

[wbergtho]

(IMG:http://www.914world.com/bbs2/html/emoticons/confused24.gif) My KEP 240mm Stage 1 pressure plate is not releasing and I've checked all the obvious things like a broken spot weld on the Boden tube (firewall & attachment by shifter), pedal box bushings, clevis, clutch cable,...etc. All the these items are great. I watched the Boden tube while actuating the clutch and it is still. The clutch won't release enough to allow gear selection while the engine is running. With the engine off, I can select all gears no problem (brand new gearbox). The car ran well and the clutch seemed to function properly for about 200 miles...then it quit releasing all the way...and found myself double clutching & matching revs to get it home. I then tightened the cable thinking it must have stretched under the strain of the KEP pressure plate..and it still won't release. I then used the "cave man" approach to determine whether the pressure plate will release manually or not. I disconnected the clutch cable @ the trans and slid a long pipe over the lever arm and cranked it over to it's maximum travel...had a friend hold it there while I got in the car (up on stands)...I fired it up and checked to see if it was released entirely and it was. It shifted into all gears properly with engine running. My question is...WHY can't I get enough clutch cable travel to actuate the pressure plate entirely...when it WAS working flawlessly for 200+ miles??? I'm starting to think that there may be something wrong in the disc, or pressure plate broken or cracked diaphram, or maybe the pilot bearing has failed causing the main shaft to spin with the engine? I won't be sure until I take everything apart and inspect these parts. Can anyone think of any thing else I may be overlooking? (IMG:http://www.914world.com/bbs2/html/emoticons/wacko.gif) (IMG:http://www.914world.com/bbs2/html/emoticons/headbang.gif) (IMG:http://www.914world.com/bbs2/html/emoticons/confused24.gif)

Thanks,

Bill

[drive-ability]

QUOTE (wbergtho @ Mar 29 2006, 09:03 PM)

Drivability, I'm glad to here it's working fine now. Could you describe the symptoms of your cracked diaphram to me? It may explain why I was "getting it all" and then suddenly "not Getting it all". I assume if one or two fingers of the diaphram cracked...you could still manually release the pressure plate like I did with a long pipe. It would take more travel to achieve the release...know what I mean? Was Yours cracked in two pieces or just a cracked line on a finger??? Bill

Mine was cracked in one place and my symptom was huge chattering. Uneven clamping and the petal was not as hard to push down. I know the stroke needed to disengage the clutch is short may be 3/4 of an inch in the bell housing. I would just make sure its moving enough outside the trans. I think the fork which sit around the T/O bearing is pined through the shaft, so if it failed you wouldn't have anything. That part of the trans looks to be really strong and not likely to brake. My fork that sits outside is around 6 inches long and it needs to pull about 1 - 1/4 inch to disengage. I can see the T/O barring etc with my trans just disconnected a small amount. I would take a look at whats going on. I know how much work this is, I had my trans out 3 or 4 times trying to trouble shoot my clutch issues. Let us know what you find.