Just replaced the clutch in my 91 W250 with the 12 1/4" Luk kit. Now the clutch won't disengage.

This is the 2nd clutch in this truck and the flywheel was resurfaced the 1st time but don't know how much material was removed. The slave cylinder pushrod had been lengthened (by the addition of a bolt welded on to the pushrod) when the 1st clutch was put in.


The old clutch had gotten very hot and was glazed so bad you could see your reflection in it and by the welded on bolt tells me it wasn't done correctly.

The mechanic said the flywheel has had too much material removed and the truck needs a new flywheel. Any thoughts please

 

Sounds right to me. How much play do you have in your pedal before you get pressure?

 

Well since they had to weld a bolt to the pushrod I'm going out on a limb here (don't worry, I do all my own stunts) and say you need to replace the flywheel.

 

With the previous clutch I didn't get any clutch response until it was almost to the floor or just coming off the floor

 

That was the worn out clutch most likely

 

Are you sure you oriented the clutch disc properly?

 

yes the clutch disc is on correctly

 

How much free play is in your clutch peddle to master cylinder? Mine was on the floor to when I discovered the eye and stud where about to depart each other.

 

I think we have solved the problem.

After much head scratching, internet searching, and a call to LuK we figured out the flywheel that was on the truck part# 3915042 will not work w/ the LuK 12.25" clutch kit because the 12.25" clutch is taller and the release bearing is not letting the clutch disengage.

So, it looks like I'll have to replace the flywheel with a LuK flywheel part #LFW301

These old goats can be a real pain but "Oh how I love them"

Thanks for the help and comments