clutch disc not releasing help!!

Ok its not funny anymore, im really starting to hate this project.... I just finished rebuilding a 318, the transmission is a new process 435 4 speed manual transmission (dodge d100 truck).

The problem im having is that i cant get the transmission into any gear because the clutch disc never releases from the pressure plate.

during the rebuild i replaced the pilot bushing and checked for free movement of the imput shaft, i was able to move the imput shaft with my fingers, the clutch disk also moved freely in the imput shaft splines and was lubricated with solid graphite in the assembly, during installation the clutch disk pressure plate and flywheel where aligned with the imput shaft removed from the transmission, i replaced the trowout bearing.

I DID NOT replaced the pressure plate. Clutch disc, trow out bearing, and pilot bushing are new, yes everithing but the pressure plate is new, i didnt have the money to buy it at the time and i dont have it now.


i removed the flywheel lower cover to check and the pressure plate never releases the clucth, i shifted the tranny to second gear and tryed to push the truck while someone pressed the clutch, it was impossible, i thought it was a problem with the clutch links because they are colombian made. so i deleted that option by pulling the clutch fork with a power hand puller, it doesnt matter how much i pull that fork the pressure plate just doesnt releases the disk.

new clutch disc has both faces is 0.140" thick, old disc has the flywheel face worn to 0.130" and the pressure plate face to 0.096" face thickness specification according to 1975 truck manual is 0.140" so i must have the right clutch disc.

taking into account that the clutch worked fine before i damaged it, coud it be possible that an old pressure plate with worn release levers cant move all the way back so it cant release the disc?


pics of the assembly...