2001 Cavalier 5-speed manual 2.2 240K
I had my clutch master cylinder replaced 8 months ago. The reason at that time was because the clutch pedal bite point had dropped down to the last / bottom 10% or so of pedal travel. After the repair, it was the exact opposite - at the very very top way too high in the first / top 10% of pedal travel. Over the last couple of months, it has again dropped to the point where I am having problems shifting because it is again in the very last tiny bit before I hit the floor. The clutch is not slipping at all. I had a new clutch kit including a new slave put in back in 2015. The reservoir is so full that it almost spills out when you take the cap off - can’t add one more drop. No external leaks.
My question is - is there any way to adjust the pedal bite point without messing with the hydraulics, fluid, or lines in any way? Given this symptom, could it be anything other than an internally-leaking slave or master cylinder (past the seals)? Can someone tell me the procedure for replacing the master cylinder? I was already upset enough before I did some price/cost estimate checking on both of these. Even though I had known the slave was part of the clutch kit, for some reason I thought price and labor would be about the same no matter which one was the problem. But it appears that replacing the slave is the same job and the same $1000+ expense that getting an entire new clutch installed is. No way I can even come close to affording that so I am hoping it is something else.
Thanks for any info or suggestions.