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Joined: Tue Dec 5th, 2017
Location: Michigan, USA
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The usual problem is misalignment of the clutch disc. Even a small amount can make reassembly difficult or impossible.
Try recentering the disc with the alignment tool. The soft plastic tools that sometimes come in clutch kits are not particularly accurate. If you can't make that tool work, a steel or aluminum tool is usually much better but obviously not as cheap.
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2003 FX4 Level II, Supercharged 5.0L V8, Headers, Duals, BW4406 manual T/C
Aussie Locker, Torsen L/S, 4.10's, Bilstein 7100 rezzies, Cadillac/Mustang rear discs, Duff traction bars
Keypad Entry, Lock LEDs, sway bar discos, Heated seats, Explorer EATC, Trip Computer and consoles
Other rides:
2016 C-MAX Energi (plug-in Hybrid)
2011 Taurus SEL (highway cruiser)
2003 Ranger 2.3L M5ODR1 Regular Cab (drudge)