While the transmission was out, did you check the following?

End of tranny input shaft. Is it smooth where it sits in the pilot
bearing? Any problem with the pilot bearing shows as damage here. Any wear
on the shaft requires replacement. That bearing also aligns and supports
the shaft.

Is the felt seal ring in the flywheel still in place and functional. This
needed to keep clutch dust out of the bearing and grease in.

Did you check the arms on the throw out shaft? These arms can bend or wear
making the clutch partly inoperable.

Is the ball cup still intact on the operating,(slave) cylinder? I have
seen the ball socket fall out or break reducing the throw available.

Hope this helps,
Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
Jens Jakob Andersen
Sent: Saturday, June 09, 2007 1:01 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Clutch problem - input needed
Importance: High

Hi,

I have a clutch problem.

For a while I have had a clutch that coudnt disengage fully. I
suspected worn pilotbearing.

Today I changed the clutch, put in a brand new LUK clutch - so nice.

The Pilot-bearing looked fine, so I didnt change it, just gave it a
little bit of grease. Used mypinky to grease it - felt fine.

When I started the engine, I STILL HAVE THE SAME PROBLEM!!!.

It feels like the clutch just doesnt dis-engage enough.

I have to switch off engine, put in gear, start engine with clutch
depressed, other foot on brake, since cars just wants to drive.

When I bleed the hydraulic system, funny symptom.
Ida depresses clutch, I open bleedscrew, clutch-pedal goes the rest
of wayto the floor.

Looks to me like some kind of problem, that the release-bearing arm
cannot turn enough. Maybe problem with the release-arm bushings?
Maybe problem with slavecylinder?

I am fully puzzled, I will get another slavecylinder early sunday
morning (used one), and try to put that on my car,and see if it solves
problem.

Anyone have ANY idea of what can be causing the problem?

And does anyone know how much the slavecylinder-piston should be able
to travel?

/JJ