I've got an ACT 2600 installed that’s been in for about 6 or 7 months. Also installed at the same time was an ACT flywheel, and TSS clutch fork. Tranny is a jdm i picked up around the same time, lines and slave cyl are all fairly new. Never had any problem with it until tonight. I left earlier tonight and noticed the clutch felt a little stiff. As I was driving it was taking longer to come off of the floor than usual. By the time I got home when I push the pedal in it is very stiff and stays at floor unless I pull it back up. Any idea what might be the deal? Also a new mitsu TOB was installed as well.

clutch sticking to the floor usually means you are losing pressure in the master cylinder, but I don't remember the clutch getting HARDER to depress when that happens, but in fact easier. I do know the slave cylinders are prone to going out though. Check your master cylinder fluid level and see if it is where it should be, and if its not I would just get under the car and see where it is leaking from.

damnit nick thats what I was typing........

ha ha, you got owned by the biggest mechanical idiot evAr

Fluid level is fine. Was maybe a mm under the full line i went ahead and topped it off. I looked for leaks and visually checked everything out but couldnt find anything.

What are the odds of it being the pressure plate? From the symptoms thats what came to mind but it was installed new with the clutch.

are you using an extended slave cylinder rod?

No, but Its never caused any issues before tonight.

act's, especially 2600's tend to eat them like cinamon toast crunch. causing engagement/disengagement issues.

lmao, I have noticed that its been harder to get into first gear. When I try and get into 1st even with the clutch to the floor it grinds a little, then feels like its not fully disengaged. I will pull it and toss on a spare or see how the rod looks. Would that cause increased clutch pedal effort though?

Not sure on the TOB. I'm hoping its something simple that doesn’t require dropping the trans. I'm going to go back out and check a few more things on it though. It doesn’t feel like the pedal hinge assembly is rusty or frozen that was one of the things I thought at first but it feels like pressure through the hydraulic system. I haven’t completely checked it out though so I'm going to go see if I cant figure something out.

Well it's not a problem with anything in the transmission. I pulled the slave cyl off the trans and fork and still got the same problem. Went ahead and tossed on another slave cyl and bled the system but its still doing the same thing. So now I’m eyeing the master cylinder. Anything else it might be or should I probably just go ahead and pull it? And the rod was in perfect shape. But an extended rod wouldn’t hurt................ nevermind you people are sick!

New development. Nevermind on the bleeding the system. When I switched slave's it leaked a little but when I tried to bleed it nothing would happen. I put the old one back on and same thing. The clutch is about 2 inches off of the floor and has pressure for those 2 inches or so. But it will not return to its original place. I can pull it all the way back up but when I press the pedal in it goes almost all the way to the floor until its gets to the last 2 inches or so then has a lot of pressure. Even with that amount of travel its still not pushing anything through the lines, so I'm assuming it has to be the master cylinder. How do I disconnect it from in the car under the dash? Its one of the few things I haven’t replaced on the car so I guess its time, could it still be anything else? Thanks for all the help.

I'm almost sure its the master cylinder. I went ahead and pulled it and will replace it tomorrow. Damn that cotter pin took me forever to get out! Almost realigned my spine in the process. Any easier ways to get that out or back in without needing a chiropractor?

Haha! Try doing it with a rollcage bar welded into the foot well.

nope, not really. a good tactic i've always used is just tipping my seat all the way back, and sliding in upside down. tilt your head up from time to time when your vision turns red

Ok need a few more suggestions. I changed the master cylinder and I’m still having about the same problems. When I press the clutch pedal it travels about 2/3 of the way and seems to do nothing then it engages the rod to the master cylinder. So it has to be something in the clutch pedal assembly right? When I push the clutch it travels very easily and does not push on the rod for the master cyl until it reaches the last 1/3 of travel. Any one have similar issues before? Also it will not return the last 2/3 of travel it brings the pedal about 1/3 off the floor then you have to grab it and pull it back up to its original position. HELP!

And god help me if I have to pull that master cylinder again! Man was that a pain in the ass. 3 hours later and the steering assembly and all the brackets are sitting in my garage.

sounds like maybe you need to adjust your clutch out

Try this. It may help, it may not. Just a thought though in case you want to check.

http://www.taboospeedshop.com/clutch_pedal_assembly.htm

Thanks for the link. Man that was a lot of fun getting the pedal assembly out of the car, and I thought it was bad working on the master cylinder! But I found my problem, the clutch lever is rounded out in the square hole. With just the lever hooked up to the pedal there is about 1 1/2 - 2 inches of free play. At the pedal that would make up for my problem of not pushing the master cyl rod until it almost reached the floor. My car is just a pile of parts after this mess. Hmm anyone have a spare lever laying around in GC I would imagine they wouldn’t cost to much from mitsu, going to check tomorrow but let me know if anyone has one I can grab. Thanks for all the information.

No problem Taxi. That's what we're all here for.

Just remember to weld the new one before you put it back in like the link shows.