I'm looking for a little help. I just finished rebuilding my 03 s with just a little over 365,000 miles. Good news, got it all back together and it fired right up. Since I had the engine out I decided to replace the original clutch, pressure plate, dual mass flywheel, throw out bearing, and guide. Now the part I can't figure out. The throw out bearing comes into contact with the pressure plate splines after about a 1/2" of travel, thus the slave cylinder does not have enough travel to fully release the clutch. I dropped the engine again figuring I had missed something, I cannot find anything not put together correctly. Any suggestions would be appreciated. Thanks,

Nik

 

Photos to explained




Shifter arm where throw out bearing should be in contact w/ pressure plate splines





Shifter arm where throw out bearing comes in contact w/ pressure plate splines...

 

My guess would be that the throw out bearing slipped off of the clutch fork during reinstall. Did you tie the shifter arm back when putting the transmission back on?