Hey all.

Converting my 92 bird over to a t5. Originally was using all parts from an 87 formula parts car. Installed everything, and clutch wouldn't fully disengage. Pedal felt fine, system bled multiple times, clutch disc not backwards, throw out bearing was in correctly.. worked fine in the parts car.

Pulled that trans, it needed a rebuild anyway.
I has a fresh rebuild v6 box around, so I ordered a mcloud 14 spline clutch and RAM pressure plate, along with turned flywheel and another new TOB.
Input shaft was cut down to proper size.
Just installed it yesterday, same story as above.
Trans was NOT pulled in using the bolts, but it was a very tight fit. Pedal felt great, same feel and travel as my DD bird. Made a longer slave rod for ***** and goggles, no change. Tob arm isn't bent either.
I thought it might be the pilot bearing slightly cocked, or the clutch sliightly misalligned. Pulled it and checked the pilot bushing clearance on both the tool and another imput shaft. It's fine. Clutch was lined up fine as well.

Even as I was pulling the trans back out, after the nose of imput shaft was out of the pilot bearing,clutch felt the same. I can reach through the floor and turn it, but clutch is definitely dragging.

Any ideas what might be up here?
Clutch is not bent, Tob is 100% installed correct, and hydraulics are traveling same distance as DD.

 

Who knows?
You had parts that worked, then switched pretty much everything that matters to new / different. Which confuses the issue.
What sucks is:
It totally sounds like the TOB has the spring clip misinstalled but you say it isn't.
It is now impossible to compare the working 87 to the non-working 92.

How well does the new disc slide on the maindrive (input) splines?

Is the flywheel truly flat? New doesn't guarantee flat.
How about the PP surface? " " " "

If you can locate a brake and clutch rebuilder (they focus mostly on truck stuff nowadays,) they will be best equipped to verify the clutch release, turn down a non-flat flywheel or PP and inspect the stuff best.

 

​​​​​The 87 never ran, so when I say it "worked", I mean the clutch engaged and disengaged fine. I changed everything because the clutch was horribly burned and the 87 trans was In need of a rebuild.

The flywheel is from the 87, but resurfaced. Only 8 thousandths had to come off, was just heavily glazed and burned in a few spots.

The clutch slides fine on the imput shaft.
The pressure plate is new, so I assume it's flat, but can't confirm. However, had the same symptoms when using the clutch/pp out of the 87 and with the v8 box.