Alright guys, so I just manual swapped my 1999 civic d16y7 with a JDM 5speed.. I have a brand new stage 2 clutch, brand new master cylinder and slave cylinder with braided metal line..
my car will drive, but the clutch pedal is loose for about 2”, after those 2” the clutch rests about 3/4” lower then the brake pedal. when i go to press the clutch i only have about 3" of travel on the pedal and it feels pretty spongy, and the clutch does not disengage tell you press the pedal damn near to the floor, then reengages about 3/4" off of the floor, it feels like there should be more movement and more pressure with a higher brake. The car WILL. drive and go into gear but doesnt feel like my past civics. master linkage is adjusted all the way out AND the system has been bled over and over to try to fix this. My slave gets about 3/4" of movement on the clutch fork aswell. I am at a loss and bout to give up and take it to the shop so this is my last ditch effort… maybe either the MC or SC came bad from new? or bent clutch fork? all input helps! thanks guys

 

Any ideas ?? Anyone?

 

Assuming you've truly bled it all out properly:

1. Look for leaks / loss of fluid. If your master or slave is bad, it'll probably be leaking.
2. Make sure your slave is securely bolted to the transmission. If you've only got one bolt holding it on, or the bolts are stripped, or something else weird, it can cause poor pedal feel.
3. Make sure your clutch fork isn't bent, broken, cracked, or otherwise damaged. Pull off the boot - how does it look where the slave pushes? Shine a light into the bellhousing - can you see any cracks in the arm near where the pivot is? Wiggle the clutch fork back and forth - does it seem like it's sitting properly on the pivot, and that the spring clip is properly installed to hold it in place on the pivot? If neither of these work, you may have to remove the transmission to further investigate. I've seen the clutch fork break at the pivot, and also be worn so thin at the pivot that the pivot pushes through it.
4. Less likely since it's not a cable clutch, but make sure your pedal cluster and firewall isn't cracked / flexing. Does it have all the hardware installed?

If you end up pulling the transmission, while you're in there I would measure the clutch disc thickness and check it against the manufacturer's specs.