Clutch has less then 20k on it, I have the skills and the tools (and a garage) so I did it my self, everything new including master and slave cylinder. Worked great for 18 months.

Tuesday I was leaving work and pushed in on the clutch, it did not disengage and the pedal stuck 3/4 of the way down. It would not return unless I physically pulled it back up.

My first thought was a bad master cylinder, I replaced that but it still happens. Slave cylinder works fine. (New fluid and correctly bled)
Dropped the trans, yoke and throw-out are fine, all move freely.
Clutch disk looks good, it wasn't stuck to flywheel or clutch plate.

The diaphragm spring seems very stiff. It's not frozen, but I need a pry bar to get it to move. (It will move)

I was out of ideas so I bolted a strap across the slave pushrod to see if maybe the line was bad, No leaks but the same thing happened, Stuck pedal.

Now I'm thinking that somehow the diaphragm spring/ clutch cover suddenly has more resistance then the hydraulics can over come.

Has anybody ever heard of such a thing?

 

Pedal break at top?

 

Pedal assembly is fine, but thanks.

 

I was looking at the parts manual and noticed a return spring on the pedal that I didn't remember. This made me take a closer look. You're right, the pedal is cracked at the top.
Do you think that could be the cause?

 

See posts 2 and 3....................

 

You're right, stupid question.
I was frustrated that I already had the tranny out and it was back in with only 2 bolts and still not working.

Phinnias J Whopee you're a genious

That was it. It had split on the front side behind the tube so it wasn't obvious.

 

LOL. Happens to the best of us.