 Clutch Failure? Twice??
I bought my 2005 Focus ZX4 ST last summer with 34,500 miles on it. In October I was driving to work one day when the clutch went away without warning. That is, with the engine running and the clutch pedal depressed fully, I could not get the transmission into any gear. However, with the engine turned off the shifter would find any gear easily and without noise. If I put the car in gear with the engine off and turned the ignition, the car would lurch forward. So that told me the clutch was fully engaged and was not disengaging with pedal depression. My initial thought was that the slave cylinder dumped a seal. I took the car to my local repair shop and the mechanic felt the problem was the slave cylinder as well. After replacing the slave cylinder the problem persisted. The mechanic then changed the master cylinder, but the problem persisted. Finally, I instructed the mechanic to replace the entire clutch assembly if he was going to pull the transmission in any event. That solved the problem...temporarily.
Late last week (5 months and 11,000 miles later), I'm driving home from work and stop for gas...when I get back in the car to leave the gas station, NO CLUTCH. This is the same exact problem as back in October. I took it back to the original shop as it should be covered under their warranty. However, after replacing the master cylinder again, the problem persists. It's not as bad this time...if you put the car in first gear and start the engine the car lurches forward but then stops and will run with the pedal depressed. However, when moving forward gear changes are brutal and may as well be without the clutch at all. The car has been at the shop for 4 days this time without success. The mechanic says he has posted on every forum he can think of without any answers. Ford mechanics are not very helpful.
I was told by a transmission shop manager that we should use only OEM Ford parts as this is a problem he has experienced before and solved by using OEM Ford clutch parts.
Anyone out there seen anything similar? Suggestions? Remember, 11,000 miles ago the entire clutch system was replaced so all the parts are new. Could it be a blockage in a hydraulic line? Actuator cable length?
I'm at my wit's end. I really like this car overall, but I can't afford a new clutch every year. | 
