2002 Grand am Clutch pedal Hard as Rock.. now Inoperative.

[Datstun240z]

So I did a clutch replacement On a 2002 Grand Am with a 2.2. I Replaced the Slave the clutch and the pressure plate. Got everything back together. Bled the system. Took it out for a test drive and it drove like a charm. Clutch was like butter to press, and fully operational. So with the Job being completed, I drove it back to the Car lot..It operated FLAWLESSLY along the way.. So I parked it and 15 minutes later get a call that the pedal is hard as a rock and can barely be pressed down. Not understanding how this could suddenly happen I went back to the car and sure enough.. it was like pressing the clutch in on an old cable clutch dump truck! It would slowely go down... Like the line was restricted. once it did go down.. I could shift into gear. and it would return quickly and go forward. So then I open the bleeder screw. pedal goes to floor like butter. (Lines good up to that point.) I then take off the plastic bleed valve assembly from the Slave cylinder. and also remove the clip and disconnect it from clutch line. I noticed the little o-ring on valve thing under the spring was cocked and wedged funny in the opening of the slave side. Hoping this was the issue i straitened it out re-seated it and put all back together and bled. I tried to press in the clutch and it was Hard as a ROCK I couldnt press down at all..Took bleed valve assembly all back apart to try a different spring.. in the process I also noticed The CAR WILL ROLL IN GEAR WITH CLUTCH LINE DISCONNECTED!! WTF! AHH Only thing I can think of is a sticking Throwout bearing on slave cylinder or bad pressure plate. I pushed in the little valve thingy on slave line input thinking pressure is holding it engaged. No such luck. Still rolls in gear. Now I think Im DOOMED to tear this trans back out which i really dont want to have to do! Is there anything Anyone knows about these that could be the issue?? Any suggestions greatly appretiated!

 

[melsg5]

Other than what you have already determined do not think anything else would account for this.

 

[Datstun240z]

Yeah, i'm Thinking The Slave Got Overextended Because Of That Darn Valve Blocking The Fluid return.. Any Idea As how To Fab A Reverse Hydraulic System To Try And Suck It Back In? Might Bend a Bar To Try & get In There.. Like The Idea Of reverse Hydraulics Tho. Cant Remember If Theres A Seal Lip That May Have got Off Edge Tho.. It Would Sure Suck To Fold That Over.. Fml..

 

[melsg5]

Interesting idea but if that thing is wedged the reverse hydraulics is only atmospheric air pressure pushing back, not the same as incompressible fluid compressed by your leg pushing on something. I'm afraid you will have to at least partially disassemble to find the problem.