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Originally posted by ez
the slave cylinder does push itself out a little bit if you remove the slave from the trans and let it hang there. No fluid escaped from what I could tell, so I don't believe air entered the system)
Normal. No problem.
Ok, just to define area of concern (from your description), your clutch is not working (lol, duh).
So from there; why is it not working? I don't believe the hydraulics are the problem either, BUT check for any kinks etc in lines and check your resevoir fluid. As you said, it was working before, and you don't crack the system at all when you do the tranny, so there's no reason that it would just go.
You can pop the rubber boot and get a bit of a visual to see if there is anything out of sorts with the arm etc. Have someone push on the clutch and watch for travel of the slave cylinder post (how far does it move? In that sense, I had a buddy with a pedal assembly on a 1g go. To prove to him that his clutch still worked we set up a bolt and nut that allowed us to push on the clutch arm. This allowed him to start up and shift it freely) and see that the clutch arm is actually pivoting off the pivot ball. If not, there is your problem.
If everything looks like it is functioning properly, you will probably need to pull the tranny to see what's going on (um, you did bolt to the flex plate, right?). I want to blame the clutch itself, but it would be unusual that a clutch is worn that far (but then again, it could be actually broken inside of the modular unit).
FWIW, I just did a tranny swap this past Saturday and it took me 9 hours, lol! Yeah, I had to pull the old tranny apart (for the bell housing) and yeah I had to pull the "good used" tranny apart and replace some (it wasn't as "good" as it was "used", lol) and yeah, I was taking pics and writing down crap for a write up (coming as soon as i write it up) and yeah I had to go out and search for a lower control arm because a bolt decided to seize up in the bushing. But it was still longer than I had anticipated. You and I both know do-do happens.
But isn't that what makes this all fun?  Captain Caveman
96 RS Turbo 11.414 @ 119.62 MSNS, Crower 2 NA cams, BW366, 10.5 comp, UDP, 60mm TB, W/A intercooler, 3.55 tranny 567.9whp 430tq
97 RS NA 13.188 @ 103.87 MSnS powered 12.5 comp, Crower 3's and 219.4whp with 175tq
98 RS DD 12.5 comp on stock ECU, LTH, Crower 2's, Koni, GC, Hypercoil, DG hats
99 OZ 5sp Stocker 15.856 @ 85.97
99 GS stocker auto 17.7@77mph!
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