[bobbyb]

Hi guys, in a hasty rush to get my coily running I suspect I may have fitted the clutch plate back to front . New complete clutch assembly all went in fine and even works, but if I depress pedal too far it wont engage gears, it will only grind teeth. Also, pedal rest height is high.
All was fine before replacement, just wanted to renew while I had the engine out. Ive tried cable adjustments, but no joy. Pretty sure I've screwed it up, but before I go ripping the motor out I just wanted to ask you Suzy nutters (experienced suzuki enthusiasts) for an opinion.
Thanks in advance..

[tonyevans]

I have personally never come across a clutch plate that will go in the wrong way round - Thrust bearing are a different matter though - I have seen them in back to front but usually stops the clutch working altogether.

[lump_a_charcoal]

Just drop the gearbox out - you don't have to remove the motor, do you?
Have never done it on a Sierra, but done plenty on other makes.

Have you looked in the inspection bung to see?

[royce]

how much freeplay do you have on the end of the cable with your foot off the clutch?

I suspect if the pedal is high you dont have enough freeplay and when you push the clutch you are going too far and the pressure plate fingers are hitting the clutch plate

AFAIK you can put the clutch plate into a sierra back to front, the center boss will foul the flywheel

I would try loosening the clutch cable until it takes up a little off the floor then adjsut the pedal stop down till there is a few mm of freeplay in the cable

[bobbyb]

Much easier for me to rip the motor out with the eng crane, 30mins and its out. Saves laying under the car (I have bad shoulders) and you have a great view when centering the clutch.
Thanks boys, I will go check those things out right now.

[bobbyb]

Do i feel like a dickhead or what?? Thanks Royce, you were right. Adjustment was all wrong, seems I had the rubber bung on the cable that slots onto the side of the engine all fouled up. No wonder the cable was tight, couldnt adjust it enough.
Working fine now.
Next job for the day..... off to Bunnings to buy a bunch of new lights for the shed so I can actually see what Im doing!!
Ps, wish I'd found this site years ago. Very very helpful.