In case someone runs into this thread in the future.
It appears the throw out bearing slipped off the fork during assembly and got jammed .. it couldnt move all the way back and was forced against the pressure plate. Partially disengaging the clutch from the flywheel.
All the parts were new.. but it still sucked. When I took off the transmission.. the throwout bearing was still jammed onto the clutch fork 90 degrees off.
Use the plastic staple when assembling the clutch (or a piece of tape or something..
apparently you can assemble it wrong and not know it.
Last edited by zed : 04-02-2008 at 01:39 AM.
Reason: add pic
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