I am in the process of replacing the clutch on my 94 Civic EX 4DR. While I had the tranny opened, I had the flywheel machined (refinished) and I replaced a broken release bolt (the clutch fork pivit bolt - see pic 2). The tranny was reinstalled, clutch bled, and now the clutch fork sits quite far back in the casing. When the clutch pedal is depressed, almost no resisitance is there until the very end and then the clutch fork hits the side of the tranny case.

Note: The rubber boot was removed to see the fork. This is the STARTING position of the fork and it moves back (to the left against the metal case) when the clutch is depressed.
I don't think the fork is pushing the throwout bearing far enough onto the pressure plate to disengage the clutch. I've read online that it is not good to get a flywheel machined because it can take off too much material and then the the parts (throwout bearing and pressure plate) won't work - making a spacer required (and undesirab;e). Also, could taking out the factory clutch fork and bending it help the throwout bearing move more? Any thoughts? Thanks.
Pic 2 (Clutch fork w/ old, and broken pivot bolt)


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