Ralph WD45, it has been a few years since I replaced the clutch pack on my WD with a used unit. The difference is that there is one fewer sets of plates in the early WD version. However, I used the setup described in the AC Service Manual for WD45 in the belief that it was OK, and the unit has worked fine for me in light duty.
The service manual desribes how to adjust the plate spacing when the clutch is already mounted on the splined shaft. It calls for a space between a pair of plates of 0.065". I believe that I used a 1/16" hex key or drill bit and removed shims at each point to get a snug fit at three points around the clutch. It worked fine from the outset, with good snap, so I have not messed with it. I believe that I can get the clutch to slip if I am pulling hard, but that is not usually the case in my light duty.
The service manual does refer to a spacing of 0.030", but that is if assembling the clutch pack on a bench, which I did not do with my replacement unit. If you have only 0.030" spacing after installation, that would explain why you do not have enough space to "snap over". If you actually put in a new clutch with no new spacers, it seems logical that there would not have been enough old spacers to provide the required clearance. You might try putting some additional spacers in.
Attached is a nice pic of a wet clutch from Tom MN. It's a good refresher if you haven't had the cover off of your own for a couple of years.
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