When I floor the clutch pedal, the main pulley is moving toward the front, like about 1/4" or more. When let go the clutch pedal, it move back. The flywheel center is grinding the engine part (stationary gear ?) when engaging the clutch.

When floor the clutch and crank start, the car won't start for long time. After bypass the clutch switch, engine can crank start like normal.

Anyone knows what possible happened? Thx

 

End play is 0.04-0.09 mm , max is 0.1 mm. There are several spacers available to get it back to spec, but, with .250" of play, I dont know if its possible. Your car wont start without rigging the clutch switch because of the friction caused when depressing the clutch, with that much end float you have metal to metal interferrence . Maybe the spacer or needle bearing has failed.

 

I would say some major disassembly is in order to figured out exactly what has blown up.

Does the clutch work?

 

I would say quit driving it if you have ANY hope of salvaging parts

 

Car can be driven with no problem except the sound while engaging the clutch (throw out bearing replaced with new unit). I stop using the car after drove back to home. Now preparing some old housings/rotors for assemble a new engine to replace the one on my car.