hey john T

what happened with the clutch

Wellllllllll I was holding off until I could finally report success but Nooooooooooooo

We pulled the tranny and the clutch n pressure plate Wednesday to inspect the pilot bearing,,,,,,,pilot was like perfect butttttttttttt I discovered the end nose on the tranny input shaft was worn badddddddddddd to where when the end went inside the pilot there was a ton of clearance i.e. it was just hanging/floating sooooooooo he had another shaft and the pilot fit into it tightly like a glove so we reinstalled everything and the shaft fits tight n right into a good smooth pilot bearing now.

New clutch disk slides sweet n smooth n correctly on the input shaft (no burrs or hanging),,,,,,,,,throw out and pressure plate all new and flywheel turned down,,,,,,,the 6 adjustable fingers on pressure plate set pretty even and to within 1/8 of throw out when clutch is at rest THOUGHT FOR SURE THE REPAIRED SHAFT TO PILOT WOULD FIX IT BUT NOOOOOOOOOOOOOOOOOOOOOO still grinds the gears

SOOOOOOO what we think now is the 50 years of wear (1960 4104 Bus) in the clutch linkage and cross directional assembly isnt giving us enough travel where the throw out depresses the fingers. Once the fingers contact the throw out and clutch poedal is full depressed (YES we already adjusted slack as tight as can so fingers arent against throw out) THERES ONLY LIKE 1/2 AT THE MOST OF TRAVEL...... We believe if pressing the pedal yielded 1/4 more inch of throw out pushing fingers deeper (i.e. more separation of plate to flywheel) she will release i.e. not still spin tranny. We have welded a bushing on the big cluth lever arm down lower closer to bell housing to yield more arm tarvel from rod being pulled but that makes pedal reallyyyyyyyy had to push down

Tomorrow we plan to remove the rear floor panel to get to where the clutch rod from up front goes to the cross directional assembly n inspet for wear n slop and interference CUZ WE THINK WE NEED 1/4 MORE OF PUSHING FINGERS SO CLUTCH FINALLY RELEASES

Any ideas on how much travel is needed against fingers so clutch releases?? Theres only like 1/2 inch travel now after throw out tightens against the fingers and I think we need at least 3/4 inch. We will also try it by tightening more slack even to the point the throw out always spins (is full agiant fingers) but at least we can see if pushed far enough it will finally release maybe???

Its a single disc push type non braking clutch on Spicer 4 speed tranny behind a 671 Detroit on a 4104 Bus

Thanks yall

John T (Who invenetd clutches anyway grrrr)

Now you're on the right track.
Check the ENDS of what you call the "cross-directional" where it rotates. Probably ball joints that have worn, or in some cases, disappeared entirely.