Dumb question - when you had the transmission out to rebuild the clutch
assembly did you inspect the pins connecting the mechanism to the throwout
bits? It really sounds to me like you might have a substantial amount of
wear in the linkage there - the pins ofttimes wear and wear the holes oval
at the same time.
It doesn't take a lot of wear there to really screw up the throw of the
clutch.
As far as adding to the shaft, replacing the shaft and the like - if it's
not massively worn it shouldn't need it, and the additions and tinkering
are just masking the real problem.
ajr
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