OK.. so heres the issue.

Recent past my buddy has been having issues getting his car into gear intermitently (sp?). Sometimes it worked fine, sometimes it just would not want to go into gear. At first it was happening really only at start up and when the car was first warming up, but recently he was having issues with it while driving.

So.. heres what we did:

1. Bled and re-bled his clutch lines. Absolutely no air in the lines.
2. Thought it could be an issue with the Clutch Master Cyl, so he replaced it (from OEM to Onmipower unit).
3. Decided we'd pull everything apart and find out whats going on.. maybe something with his release bearing.

So.. we pulled everything apart and found this:

See the groove the release bearing has worn into the pressure plate:


And now see the difference in height between the center of the bearing to the "next step down" on the bearing. The new bearing we got was pretty much flush (same height).



So.. yesterday we replaces the clutch, pilot and release bearings.. and got a new lightened flywheel to boot.

Once it was all back together, and was in neutral.. it goes in and out of gears fine.

Now, with the car off, and in neutral, the car statrts fine, but it wont let you shift at all. If you start the car with it in gear, the clutch is engaged and it wants to start IN gear.

WTF?!?!?!... Were trying to get this wrapped up today, Sunday so he can drive to and fro' work.

TIA for any help.