edit: Just to be very clear car is a 2006 cobalt ss/na 2.4 5 speed
So I just replaced my clutch the other day, boy was is a pain in the ass doing it on my garage floor. After a couple hiccups I buttoned it up the other day and have attempting to bleed the clutch for about 3 days now. First a little background, parts I installed are:
KY stage 1 clutch
Exedy lightweight flywheel
NEW TOB from KY, not sure of company but its OE specs
Followed the how-to on here pretty closely and help from a friend on here got it done. Everything is currently hooked up except the fuse box/pcm so I have more room to work on bleeding.
At first I tried the manual method with a buddy (clutch in open/close bleeder clutch out) with ALOT pedal pumps in between. After a while of that not working at all I gave up.
Then I purchased a vacuum bleeder from harbor freight, did almost the exact same thing with the buddy and again got absolutely nowhere.
After this I followed the GM build book on using a vacuum bleeder at the reservoir cap explained in this thread:
Correct way to Bleed Clutch
Now this procedure did give slight pedal pressure and the slightest amount of pedal return when fully depressed but the pedal still would not return fully and was certainly not as firm as it should be.
Also during all of the processes the amount of fluid in the reservoir hardly ever went down, maybe an ounce if that.
I was told by a couple local mechanics that a power/pressure bleed may be needed to solve the problem. One came over with a motive pressure bleeder and I made a cap to fit for this. After pressure bleeding pedal went even softer and never returned at all anymore. Also even with 25psi on the pressure bleeder almost no fluid was coming out at the bleed screw on the transmission.
At first I was thinking it was just a pain in the ass to bleed, now I'm thinking it might be a bad master cylinder. Can anyone give insight/help? I'm about to remove the master right now to see if I can bench test it but I'm not even 100% sure how to tell if it's functioning correctly.
Thanks for any help guys