4 speed swap problems

[marksp1981]

Hello All, I have a 1984 k20 4x4 with a clutch linkage problem. I bought this truck with no drivetrain but it was originally a 4sp truck. I swapped in a 4 speed and 205 t-case I had from a 78 gmc 1/2 ton 4x4. The problem I'm having seems to be with the z-bar, clutch release fork, and return spring. When I start the truck and push in the clutch to put it in gear the clutch isn't working and while the clutch is depressed it makes a knocking sound.  Also if I adjust the clutch linkage to minimize free pedal travel when I depress the clutch the clutch release fork binds in the bellhousing. While disassembling the donor 78 gmc I lost the clutch return spring I had to buy a univeral version, and made an educated guess on where it should be located. Does anyone know where how the return spring should be installed. I've already pulled the engine once to double check everything and ended up replacing the fork, but ended up with the same results. Any advice? Thanks for any help.

Mark

[Captkaos]

Are you saying you can't start the truck because it isn't working?  Describe clutch not working.

[marksp1981]

Sorry, I can start the truck but when I depress the clutch to put it in gear I can't put it in gear. Also makes a grinding/thumping noise.

[marksp1981]

Here are som pics, anything look wrong 

[zieg85]

Switch around the adjustment piece to have a straight push.  The spring is wrong but I haven't had a manual clutch in a while, both mine are hydraulic or I would shoot a pic.  Blazin may have a pic in his collection. 

[355shortbed]

looks to me the spring should be a little bit farther foward on the frame so that its not pulling so much at an angle. oh and did u put a new clutch in?? did u make sure u put the clutch disc in the correct way. sounds to me like the same problem i had. i put disc in backwards rushing, and had to slide trans back to change it.

[marksp1981]

I double checked the clutch when I pulled the engine for the second time. The clutch plate had "flywheel side" engraved on one side and that side went against the flywheel. I've also had the return spring mounted further forward on the frame but had the same results. I'll try moving the spring again if ever quits raining.  This is driving me nuts, this drivetrain came out of a running/driving truck and everything worked fine.

[Captkaos]

adjusted properly is should have about 1-2" of free travel before starting to engage.
Is the clutch assembly new?
Usually knocking is from the throwout bearing.  does it only do it when engaged?
Did you install the throwout the right way?   Collar OVER the fork?  Is the fork spring broke?
It sounds like it isn't disengaging enough.  It will go in gear with the engine off right?
Symptoms of a clutch disc backwards is the clutch pedal can't be pushed and you can't crank the truck. 
Are you cranking it in Neutral and then trying to put it in gear?

[marksp1981]

Well I finally figured it out. I pulled the engine again and immediately noticed that the throw out bearing failed, and upon further inspection of the clutch and pressure plate. I noticed that the washers I used behind the pressure plate bolts had pinched the clutch disk and prevented it from turning. So to make sure everything was on the up and up this time I purchased a new clutch pressure plate and throw out bearing. Works like a charm now.  BTW if any of you guys are in the Louisville area and need a clutch for anything check out Kentucky clutch www.kyclutch.com. I got everything mentioned above plus my flywheel turned for $95.