Last PB brings up a good point with air in the slave system. I've heard stories where guys really fought air bubbles trapped in the slave cylinder and line after a clutch replacement. Also, any sign of fluid leaking from the slave line or cylinder could also indicate air being drawn in. Be sure these components are tight and carefully bleed the cylinder. Tapping on it helps any bubbles to rise to the top.
If your clutch master cylinder seals are bad you will not get full actuation pressure and less than full disengagement. Any fluid leakage around the master cylinder could indicate air getting into the system there.
I think you have to start at the peddle and shift knob and just carefully inspect everything in the clutch and shifting systems.
Somehow we'll get to the bottom of this.
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