When to change clutch plate of lancer2004. i mean after how many km

A grinding noise means something is 'rubbing'. Is yours a fluid operated clutch or a cable operated one? A new cable operated clutch can sometime need adjusting and a fluid setup will need bleeding to get any air bubbles out of the fluid lines. Both of these can stop the clutch plate moving far enough causing noise AND damage. If you take the clutch off again Take a very good look at it to make sure the grinding hasn't damaged the friction material on the clutch plate
Was the clutch plate lined up correctly before you refitted the pressure plate? Some clutch kits supply a special splined tool to keep things lined up as you tighten the pressure plate down. Even if the plate is slightly out of position it won't sit properly and drag on the flywheel surface.

It is still a bit unclear what is going on here, when you say it seems to work, do you mean the clutch disengages? Can you change gears OK with the engine running and the clutch depressed?

When you say it does not engage the plate, do you mean the vehicle does not move? To change gears it must DISengage the plate, not the other way round.

Sorry if I seem picky, but I'm trying to get it all straight. If you can change gears OK with the engine running and the clutch depressed, but the vehicle does not move when you let the clutch pedal up, then the clutch is possibly worn out and needs replacing.

If the opposite and you cannot get it into gear with the clutch depressed, then the clutch throwout fork has possibly broken, which is not uncommon. Alternatively but less likely is that there is so much air in the clutch hydraulic line that it has become ineffective.
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When the clutch was replaced was the slave cylinder also replaced? How about the throw out bearing? These are the first things I'd be looking at. When you have premature failure of these components, it comes down to the person(s) driving the vehicle or the components, in this case 2 clutches in a short amount of time plus 2 different drivers = component failure. Slave cylinder not pushing / pulling the throw out bearing enough or the bearing may be hanging on the input shaft, did you reface the flywheel or put a new one in?

If you accelerate especially when using high gears such as the 4th and 5th gear and the RPM is able to increase freely with the speed struggling to catch up with the RPM, it means your clutch is worn out and is slipping.

You need to get the clutch replaced in order for this issue to be rectified, especially if your clutch have not been changed before.

it is very possible that the clutch plate is in the wrong way round and the clutch hub is hitting on the flywheel bolts

means a box out again and the pressure plate off to change the clutch plate around

Jim,
by law, the VIN should be visible when you look at the left lower windshield of the vehicle, normally fixed to the inst. panel. You can also find it printed on the certification label you find on the door latch area of the drivers door when opened.

check out the operation of the clutch system .IT is difficult to rationalise a hydraulic clutch because if it is slipping that means that the pressure plate is being held off and not fully engaging but it also means that when pressing on the clutch the there would be no problem changing gears . But if you have a cable clutch operation then it is possible that the cable is jamming inside the outer cover and holding the pressure plate off ( slipping) and gear problems. If it is cable then replace the cable first. If hydraulic then it may mean box out for a new clutch kit.

the noise you hear is the thro-out-bearing .when you apply the clutch pedal it applies pressure on the pressure plate .the noise stops until you let out the clutch again,the bearing can be replaced without replacing the whole kit,clutch ,pressure plate,thro-out-bearing if money is a issue,...Merry Christmas.

If you mean that the clutch will slip when under load, then it's the pressure plate that's bad. It's a common Toyota problem. It's worth it to change the entire set-up { pressure plate, clutch disk, and throw-out bearing ] as the labor costs will be the same, and a clutch package is less then a pressure plate alone.

between engine and transmission has what we call clutch. it will not work well if it has broken or sliding clutch. check pressure plate,clutch disc and release bearing.