I have rebuilt my clutch pedal assembly more times than I'd care to mention here with the JNZ tuning kit. The best way to explain the failure would be that after the rebuild, I'd press the pedal in and it would be super hard to press in. I'd persist figuring it was just the heavy aftermarket XTD pressure plate. after pressing it in to the floor, the pedal would go limp and would not return more than an inch from the floor. The pedal would feel like a piece of tin afterwards.
Upon removal and inspection, the weld would not be broken and nothing had noticeably moved or shifted.
However, when the clutch bracket rod goes into the white plunger, it now has way too much travel and leaves the white plastic piece resulting in the spring coming off.
So after this happens, I am getting a bunch more play, but there is no evidence of it at the weld or the clutch bracket.
I finally found what I believe to be the cause.....frozen clutch slave cylinder (wouldn't move and had rust all over it). I replaced the clutch master and slave, but I am sick of redoing this job over and over.
What could cause the plunger to move out too far as described above when there is no evidence of play besides that...no broken welds...nothing.