clutch problems

[paulsaveo]

I am in DESPERATE need of help. I have a 2004 Chevy aveo 5 speed manual transaxle. when I press the clutch pedal it goes halfway down before you can feel anything. when the clutch pedal is all the way down, I can start the car, when I try to put it in reverse, it just grinds and wont go into reverse. when I put it into any forward gear, i have to force the shifter into position but it will go into a forward gear without grinding I just have to force it. So far I have replaced the clutch (sachs kit with clutch plate, pressure plate and through out bearing) I installed a brand new clutch release lever (old one was bent), I also installed brand new slave cylinder and brand new clutch master cylinder. I have manually bled the clutch system 4 or 5 times, I have also power bled (power flush machine) 8 or 9 times. I need help

[benzino]

it kind of sounds like the shifter isn't alligned properly

[paulsaveo]

Im sorry, I forgot to mention in the original post, when the car is not running, I can shift into all gears properly. I marked the shift lever rod before i disconnected it so I wouldnt have that as in issue. It seems as though their isnt enough pressure in the hydraulic system so the pushrod in the slave cyl isnt fully extending, almost as if their is air in the system. I have manually bled and power bled the hydraulic system numerous times, Ive probably run 16 quarts of fluid through all the bleeding ive done. yesterday before I left work, I got in my car and everything worked properly for 2 or 3 minutes, no issue with shifting or anything, but after 2 or 3 minutes, it started acting up again. I may reinstall the original clutch master cylinder and see if that makes a difference

[paulsaveo]

For anyone that has been reading this thread, my Aveo is fixed. The brand new master cylinder I installed was faulty. I reinstalled the old master cylinder and it shifts perfectly now. It is now time for a "for sale" sign

[Daniel]

Glad your Aveo is fixed.
Do you know the reason why the fork lever was bend?

[paulsaveo]

Not sure, my guess would be stress and fatigue from 144,000 miles of driving paired with worn pressure plate fingers and bad slave cylinder that over exerted the pushrod and put too much pressure on the lever