I have rebuilt my 2.0L and am down to mating trans to motor. When I did this I noticed I have no free play in the t/o bearing arm. I have measured and does not appear to be pressing the pressure plate fingers but is on them. Is that acceptable? I expected to have some level of free movement in the arm. Is there something else I can check? Flywheel, clutch disc, pressure plate and Throwout bearing are all new. Crank, flywheel and pressure plate was balanced at machine shop. Except for the flywheel that was completely shot all measurements on new parts Click to view attachmentmatch old parts except slight wear on disc.
Thanks,

Put a thick washer under the throwout pivot, see if that helps.

I had 6 vw bugs and a van before I got my 914. When I first went to adjust my clutch I did it like I would my VW's, a little play in the pedal. Wouldn't disengage, nothing but grinding. So I adjusted it more, and more and with the cable taunt where the throw out bearing was pressed into the fingers of the clutch plate it shifted. I may be wrong, but close is not a problem. Like mentioned add a washer under the pivot, I've read that before here.

In my six with KEP clutch no freeplay is about the only way that I can get into reverse and first. It seems strange to me, but even if you put in say 20 mm the bearing is still always on the fingers. It appears that the engineers decided that if it is a bearing in a car it should be spinning.

The pivot bolt behind the fork had 1 flat and 3 spring washers. I went down to just the flat washer and how have 1/4 free play. Thanks

Don’t do this. This will exacerbate problems by forcing the TOB even closer to the flywheel.

The only way for the space between the TOB and pressure plate to narrow is if the clutch bits are protruding. When the PP and disk are bolted on, can you move the disk at all? Is the disk hitting the bolts for the flywheel? Is the disk in upside down?

Have you replaced all the wear parts for the clutch fork ?,I would not have thought you would have an issue with all new parts , is your pedal assembly in good condition ? ,mine was but the clevis was very worn and and the clutch pivot arm was all flogged out ,bad enough to need the hole welded up and redrilled....worth checking before you pull the box to shim the pivot ball ,cheers.

Glad you got things worked out. keep us updated with your project

iI the Pressure plate sticking on the locator pins? Try to remove the pins and mock up the assemble again and see if the fingers are compressing o the clutch