1990 Mustang, T-5, stock bellhousing, stock flywheel, stock quadrant and cable.
I pulled the trans and removed what I thought would be the factory clutch. The only marking on the clutch is from the manufacturer - Valeo. The pressure plate fingers stick out much farther than the "factory" clutch I purchased.
The clutch I put in is a Duralast clutch made by Valeo. P/N NU31175 from AutoZone. It's not my first choice in clutch...but my wife bought it for me for Christmas, I read decent reviews, and with a lifetime warranty, I'll put a few hours in every few summers. (I drive about 1k miles a year).
I installed the clutch and noticed that the release arm did not have the throw that it once did. Not thinking much of it, we put the car together only to find that the clutch would not disengage. When trying to start the car in gear, it would just lurch.
We pulled the clutch fork towards the engine and lifted the clutch pedal and that gave us just enough throw to start the car in gear, but I couldn't move the shifter out of gear or even hint at taking my foot off the clutch pedal.
I went to autozone and got another clutch for comparison. I didn't notice any difference between the one I installed and the one in the box at the store.
The only thing that I could think is that the clutch pivot ball needed adjustment. I threw a couple washers underneath of it and bolted everything back up. The throwout bearing now rides just on the fingers of the pressure plate. I have good fork travel, decent clutch feel, and good pedal travel. However, the clutch still won't disengage. I can start the car in gear now, but that's it.
My only guess is that the clutch kit is bad. But I'm open to any ideas and suggestions before I tear into the car again.
Here is the distance between the throwout bearing and the clutch fingers on the new clutch.
Here is how I adjusted the clutch pivot ball. I can't tell if it's stock or not.
Later I'll try and get video of the fork travel. Any help GREATLY appreciated.