I took my S to the shop for clutch replacement, because I didn't have a time to do work myself. I went with Exedy clutch kit from Ebay. After the install it I took my car for a ride and it rand perfect. After like an hour of driving I went to highway and WOT all they way until red line and ass soon as I press the pedal to switch gears from 4th to 5th my pedal went to the floor and never came back. I took it to a shop and it was Clutch release ford which wasn't in its place. They put it all back and car ran good for 2 days. I was going to work when on my last turn I WOT in 3rd gear and same thing again, pedal went to the floor. I parked the car at the work and waited for work to end. Guess what, pedal would go back to normal after I pump it, but car wouldn't start. Called a tow truck, and when we get to shop, turns out that same Clutch Release fork came off of its place and got stuck with clutch. They fixed again. But i am afraid it is gonna come back. What could be the reason for all of this?

Sorry for my shitty English in advance.

 

the fork is held by a latch at the bellhousing -- between the fork pivot shaft and the bellhousing fork holder latch -- one of them is worn out.

 

So you saying now I have to take my tranny out again and replace those parts? Damn, that's crazy.

 

not necessarily. They could have bent out the holder that's bolted to the tranny. If you pull the fork out again, you can use a pry bar or a pickle fork to bend the holder closed a little more and see if that'll solve the issue.

 

That's what he actually did, and so far car runs good. But, I am gonna wait like a weed or so, if it runs good with no problems I will leave it as is until next time tranny gets dropped.

 

I believed you can pull the fork out.
Get a flashlight and try to bend the tab that holds the fork pivot shaft at the bellhousing.
You might be able to get away. (same what jordan was saying)

 

arent you suppose to break in the clutch? 200-300 miles before ripping gears...

 

Yeah, I should. But I am Inpatient.

 

Ok. Here is the Update. I didn't wanna use mechanics again, so I went ahead and replaced Clutch Release fork and its hanger myself. But what I experience now is that, if in second gear I hit vtec (up to 8k rpms) my clutch pedal drops half way. Lets say pedal is 4" away from firewall, when I press it to change to 3rd gear its engaging point drops to about 2" from the firewall ( just an example). Could it be from the fluid, since they didn't put new fluid, they just reused old one? Or should I look for new Master and Slave Cylinders?

 

Does this happen every time? Or just randomly? If it happens every time i would imagine its still the clutch fork issues.

If its random then yes it could be your master. You can exchange the fluid with a syringe or turkey baster yourself and then see how it feels after a good bleed. If the problem still persists then you might want to look into a master cylinder.

As for the slave, once they go, they usually dont work at all so you would know if it was that.