Ok, so my '91 RS2000 has been fitted with the MTX75 gearbox from a MK1 Focus diesel. It uses the concentric slave cylinder from the Focus, but the flywheel and clutch from the RS2000. The problem is, it doesn't work! The clutch never full releases, so the clutch slips. Using an endoscope inside the bell housing, the pressure plate fingers are basically touching the housing of the slave cylinder, which makes me think that the slave cylinder is permanently pressing slightly on the clutch, making it slip.

What flywheel/clutch should I use? I bought an LUK clutch for a MK1 Focus diesel, but it's only 230mm and there is no way it will work with the Escort RS2000 flywheel.

Do I need a MK1 Focus RS flywheel and clutch? I'd rather avoid that, as it's big bucks and the car is only running near-standard power. Would a boggo MK1 Focus 2.0/diesel one work? From what I can work out, these all seem to be 230mm, not the 240mm of the RS2000/FRS. What about a Mondeo one?

Help required, as I (and the garage who are now helping out) are running out of ideas!