Clutch cross shaft knowledge....

I had a similar problem when I went with hydraulics for a while.  I wound up creating a longer pushrod for the master cylinder.  The original was not getting enough throw.  When your foot was off the pedal the pushrod was not making contact with the piston in the MC.  Adding an inch solved that.

The hydraulics work perfectly.....Its the cross over shaft travel that seems to be the problem.

It's possible someone put on a late longer 100mm clutch arm vs the earlier 90mm length arm. This would result in less pedal effort but also longer pedal travel.

But first, is this hydraulic setup actually designed for the car (VW) as a kit (like SACO) or something someone cobbled together themselves. Mounting/pivot points (pedal ratios) and master/slave diameter ratios must all be designed correctly so it creates the same amount of pedal/throwout travel as the original setup. It could also be a matter of changing the transmission side plate/cutting off the clutch cable mount to a use different mount that will work better with that slave cylinder. If it's not done right it could create the same issues you're seeing.

Can an "early" throwout bearing be mounted on a "late" cross shaft or vice versa???

Or has anyone had a cross shaft with a miss indexed arm spline???

Can't open it up at the house. Too much going on and no room....  About 3 weeks until I can get a competent shop to look at it...   GRRRrrrrr....  

Early bearing and late shaft should make some nice loud noises as the clutch quickly destroys itself. I doubt the other way round would fair much better.

I don't think the clutch arm and shaft can be mis-indexed. I believe they're both partially splined so they only go on one way.

The hydraulics are as specified by the original manufacturer.....   Its starting to appear that I might have a 90mm. arm unit when a 100mm. unit is required...  I'm assuming the "arm(s)" are on either side of the input shaft...

The shaft indeed has only a few splines, but I was wondering if "Heco in China" had struck again....

After 2 in / out with the tranny, the problem was discovered to be nothing more than the cross shaft actuator arm being installed backwards.....   Lot of grief for some one elses error.... 

I've never heard of this one before....   Its genuinely weird....

Glad that's out of the way. Full speed ahead my brutha! 

Glad you got it sorted, Leon. Now get it dialed in my friend!