Evening All,
Recently refreshed a gearbox for my 89' 998cc, as the original wouldn't hold second and was starting to crunch into third. New bearings, baulkrings, layshaft, second gear, detent balls/springs etc etc. A budget build but repalcing all worn components. My first gearbox build, following various guides and some great threads on here. Re-used the original verto clutch which looked servicable with a new thrust bearing. Primary and idler end floats checked and new thrusts/C clip installed to get all into tolerance. Whipped the engine out and swapped the gearboxes over.
Chuffed to manage a run round the block with all gears selectable. However, 1st/2nd can be quite hard to select with the engine running and stationary and reverse goes in with a crunch unless the car is stationary with the clutch engaged for a good 20 seconds or so. All gears select lovely with the engine off. On the road 1st/2ndselect better but notchy. 3rd/4th seem fine. Suspected the clutch was dragging slightly.
Since renewed all the mechanical clutch actuating components as the ball end was worn and bled up the hydraulics. Checked I was getting full travel of the clutch plunger (6.5mm as per the Haynes manual for a verto) No change. Tried backing off the clutch stop bolts to allow more plunger travel, still no change.
Tried jacking up the car with the front wheels in the air and selecting gears with engine running. Small amount of movement from the wheels as the gear is engaged and then no further movement of the wheels suggesting the clutch can't be dragging badly?
Stripped the clutch out with the engine warm and checked the primary gear spins freely on the crank, which it is. Measured 5 thou end float.
Any ideas before I bite the bullet and buy a new clutch?
Normally I would just replace it but the sound of getting the clutch/flywheel balanced sounds expensive when the gearbox rebuild exceeded the budget 
To summarise:
Gearbox rebuilt
Original clutch (verto)
Slave bled - getting full travel of the plunger to the stop on the wok.
New plunger, clutch arm, clevis pins
Primary gear doesn't appear to be pinching the crank.
All advice welcome, many thanks!
