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"Not the pressure plate, but the flywheel can be put on 7 different wrong ways."
Crap. Then this is the problem. I think I must have confused it with small block fords, where the bolt holes in the crank are unevenly spaced so the flywheel/flex plate can only bolt on in a single orientation. This would also explain the hesitation, if the engine is firing against the starter.
Well, time to pull it all apart again, then. I definitely got this wrong. I had the engine on TDC according to the crank pulley (which in retrospect I should have double checked in case the rubber has worn and it has slipped). I popped the flywheel on with the missing divots by the CPS, the bolts lined up, so I tightened it down and put it all together. If the missing divots are supposed to be by the starter opening this is 100% the problem.
As usual, one of my dumb mistakes. Unfortunately fixing it involves dropping the transmission again!
Thanks as always, I've got my work cut out for me.
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