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I have just refitted engine and G/box with a new Xtreme HD 1.6 clutch kit (inc new throwout bearing). It has an new master and slave cyl and has been bled with new fluid twice. The clutch will not disengage( I can just get it in 1st when the pedal is on the floor) - there is about 12mm of slave cyl throw. I even fitted an 8mm thick nut on the end of the slave cyl rod to see if that helped but it didn't.
Does anyone have any ideas? - I will ring Xtreme in the morning.

Has the pedal been adjusted?

How did the clutch look when you had it in place? Do you remember? Sometimes they need shimming to set them up correctly.

Are you sure the clutch plate went in the wright way around

The pedal was adjusted to spec this arvo.

I fitted the clutch to the flywheel over a week ago but I remember trying the clutch plate both ways and it would only logically go with the raised spring side into the cover (i.e. away from the flywheel).

Does the throw out lever pivot bolt have adjustment in it - although I thought putting the nut in front of the slave cyl pin would have fixed that.

I remember 40 years ago having a cracked throw out fork who's crack closed up when not loaded - it was difficult to diagnose as the end of the fork moved the required distance. but that engine only took an hour to remove.

The slave throw/extension seems about right to me, so it would indicate something is not right downstream i.e. release lever and/or bearing, clutch plate, pressure plate etc.

I agree with JBT. Just checked my throw out movement and seems to be 13mm.
Have a look at topic "New Clutch = No Gears". Hope this Xtreme problem is not yours!

Thanks for the posts
I just read the other posts Trader referred to.
Hmmm - looks like mine is the same story. I rang Xtreme this morning - they said they "weren't aware of any problems, that maybe the pressure plate needs wearing in - take it for a long drive and see if it improves could take 1000kms " so I did about 100kms and if anything it was worse when I got back home - nearly impossible to select reverse unless the motor is turned off. I also fitted a 10mm long spacer to the end of the slave cyl pin - it helped a bit initially.
Xtreme said if it is no better pull it and send it back to SA to have it checked - that did not impress me as it would be about 10 days till it was returned.
So looks like the gearbox is coming out again and i will measure the new V/s original. i may even put orig back in as I do not like the heavy foot pressure it needs now to get the pedal to the firewall.
Looks like more skin off the knuckles

Mine took a while to settle in before the take-up-point stabilised.

It was set when I picked it up and was too high by the time I got home (approx 7km)
Did about 1000km and 5/6 adjustments of the peddle before it settled down!

I had a similar problem when I installed a Xtreme hd clutch in my old clubman, I couldn't select any gears when pushing the clutch in. 10min of adjusting the clutch pedal and it worked perfectly.

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PhilM wrote:I fitted the clutch to the flywheel over a week ago but I remember trying the clutch plate both ways and it would only logically go with the raised spring side into the cover (i.e. away from the flywheel).

It should say on the pressure plate somewhere 'This side to flywheel' or something similar.

I pulled the gearbox out - After much measuring and checking I found the flywheel with a hot spot 75mm long in 1 area and no wear marks anywhere else (100kms). so i sent it air freight back to xtreme. they rang me to tell me the pressure plate had a bent diaphragm spring ring which caused the problem - they rebuilt it and sent it back air freight it arrived today so I will put it in over the weekend.
Also trying to get a new roof to fit - 70mm short of latching - after 8 hours of work. not happy with MX5 parts suppliers at the moment

that is very poor indeed. In theory it should cost you nothing i.e. they should pay the freight both ways for supplying a product not fit for purpose. They might even give a refund for the item. If the thing was fitted by a local company using a clutch sourced in Au they would probably have some deal for them to recover their labour. No one was going to guess what the fault was.