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I'm not sure I'm understanding your description correctly, but when the clutch is fully installed, the release plate (the part that sits on the three release levers and is contacted by the throwout bearing) should be roughly level with the surface of the clutch cover (the part you bolt onto the flywheel.) I'll try to attach another photo showing how this should look -- you have to look between the engine and the transaxle, but you should be able to see a side view of the clutch assembly.
Bolting down the clutch cover moves the pressure plate backward (away from the flywheel) and this action pulls the release plate down closer to the cover.
From your description it sounds as if this is what you've got, so it doesn't sound as if your clutch cover is defective or installed incorrectly. I'd still check the disc to make sure it's facing the right way.
One other long-shot thing you might check, just because it's freaky, is the slave cylinder. I had this happen on my last clutch job. The pedal felt mushy, with no definite stop until it hit the floor, and I couldn't find a setting for the freeplay adjustment screw (on the bellhousing) that would BOTH get the clutch to hook up firmly AND avoid having the release fork hit the clutch cover bolts when I stepped on the pedal.
It turned out that the problem was in the slave cylinder, not the clutch. There's supposed to be a little internal snap ring inside the slave-cylinder bore, under the rubber cover. It limits the forward travel of the slave cylinder piston. On my slave cylinder, this snap ring had jumped out and gotten lost. That meant there was nothing to stop the piston moving forward too far, making that awful noise, and if I tried to adjust the freeplay screw to avoid that, the clutch wouldn't hook up. Once I realized the snap ring was gone, I just went to the hardware store and got a new one and snapped it in. Suddenly the pedal had a firm stop and I was able to set the freeplay correctly.
I'm told it's very common for these snap rings to pop out, and it's easy to overlook the fact that it's gone, so it might be worth checking as long as you've got the slave cylinder loose from the transaxle.
posted by 68.227.170...
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