Expert: Sean Halliday - 1/16/2009

Question
I HAVE A 1997 (MFG. DATE 11/96=EARLY 1997).  THE CLUTCH IS NOT FULLY
RELEASING WHEN I TRY TO PUT IT IN GEAR.  WHEN RUNNING, I CANNOT GET
IT TO GO INTO ANY GEAR.  I CAN PUT IT IN 2ND AND (WITH CLUTCH PEDAL
PUSHED ALL THE WAY DOWN). IT WILL START, BUT ENGINE DRAGS, CAR
CREEPS FORWARD, BUT WILL GET GOING.  I CAN "POWER SHIFT" AT VERY LOW
RPM FOR EACH GEAR, BUT IT IS A STRUGGLE.  CANNOT SHIFT INTO REVERSE
EITHER, WHEN STARTING, BUT CAN, WHEN IN GEAR,  JUST LIKE STARTING OUT
IN 2ND.  IF I TRY TO SHIFT INTO REVERSE FROM NEUTRAL (ENGINE RUNNING),
IT CLASHES  GEARS SEVERELY, AND YOU CAN HEAR THAT THE CLASH SOUNDS
VERY FAST.   I REPLACED THE SLAVE CYLINDER, THEN THE CLUTCH  MASTER
CYLINDER,  BLED SYSTEM THOROUGHLY (NO AIR IN LINES),  BUT STILL NO
CHANGE.  I CAN SEE THAT THE SLAVE CYLINDER DOES ACTIVATE AND PUSHES
THE SPRING LEVER FROM THE BELL HOUSING ABOUT 3/4" TOWARD THE FIRE
WALL.  I SEE THAT THE OLD DUST BOOT WAS "FRIED" AND VERY BRITTLE.  
PIECES OF THE BOOT HAVE DEFINITELY FALLEN INTO THE HOUSING.  I DON'T
KNOW IF THAT COULD BE AFFECTING THINGS.  ALSO, WHEN I REMOVE THE
SLAVE PUSHROD, THE CLUTCH SPRING LEVER STAYS IN PLACE, BUT LOOSE, IN
THAT I CAN WIGGLE IT AROUND WITH MY HAND.  IS THAT NORMAL?  SO I
HAD WORK DONE ABOUT TWO  YEARS AGO WHEN THE HEAD GASKETS BLEW.  
NO ANCILLARY DAMAGE, BUT I HAD AN INDEPENDENT SUBARU REPAIR PLACE
DO THE JOB.  THEY HAVE A GOOD REPUTATION AND DEFINITELY KNOW
SUBARUS.  THEY ARE ALSO VERY COMUNICATIVE AND WOULD  ANSWER ALL
MY QUESTIONS (I'M A PRETTY GOOD "BACKYARD" MECHANIC).  THEY HAVE
ALSO HELPED WITH MY QUESTIONS OVER THE PHONE REGARDING THIS
CURRENT PROBLEM.  LAST THOUGHT WAS THAT MAYBE THE PILOT  BEARING
HAS GONE BAD.  I BOUGHT THE CAR FROM A USED CAR DEALER, WHO HAD
PURCHASED IT AT AUCTION.  HE WAS VERY FAIR, AND ALLOWED FOR ALMOST
FULL COMPENSATION FOR NECESSARY REPAIRS TO MAKE THE CAR RIGHT.  
SINCE THERE WAS NO HISTORY ON THE VEHICLE, I HAD THE TIMING BELT,
AND ANYTHING AND EVERYTHING ELSE THAT COULD BE DONE AT THE TIME
DONE.  SO, THIS INCLUDED A 4-PART CLUTCH REPLACEMENT.  SUBARU OEM
PARTS WERE USED, AND MY RECEIPT SAYS THAT A CLUTCH KIT WAS USED
($275.00) AND THAT THE FLYWHEEL WAS RESURFACED.  I HAVE AN
APPOINTMENT TO RETURN THE CAR TO THE SAME SHOP THIS COMING
WEDNESDAY 1/21/09.   THEY SAID THEY WOULD CHECK IT OUT FOR ME AND
LET ME KNOW WHAT'S UP.  THEN THEY'LL FIX IT AS REQUIRED.  AS I SAID I'M A
PRETTY GOOD MECHANIC, BUT I HAVE NEVER PULLED THE ENGINE ON
ANYTHING EXCEPT OLD  VW'S AND MY BOAT.  IS THAT SOMETHING I COULD
DO MY SELF WITHOUT TOO MUCH TROUBLE AND FRUSTRATION.   ARE ANY
SPECIAL TOOLS REQUIRED, ETC.?  THE CHARGE TO R&R THE MOTOR IS
$450.00.  WELL, THAT'S ABOUT AS THOROUGH AS I CAN BE.  THANKS FOR
YOUR PATIENCE IN READING THIS.  ANY OTHER THOUGHTS ON WHAT I CAN
DO BEFORE BRING IT IN?   THANKS, CHRIS

Answer
If the hydraulic pressure is ok and you still have no clutch, then the clutch itself needs replaced.Replace it as a kit complete with pilot bearing.The pressure plate seems to have failed.Removing the engine on this car is complex and not an easy job.