Where does your clutch release?
 

Every since I reinstalled my NV4500 (after the last one let go) I have had a hard time getting it in gear from a stop. We didnt bleed the line out, as the guy helping me convinced me at that time that we didnt need to since we had just unbolted the cylinder from the trans and didnt open the line. I usually have to go to 3rd first then back to second and the clutch doesnt start to grab till almost all the way out on the pedal. I am pretty sure the clutch isnt going out as it doesnt slip even under WOT from a slight lug. Wonderind if the slave cylinder is getting weak as sometimes if I pump the clutch before I try to go into a gear it will go right in. I really didnt think this trans would last this long so I didnt let it bother me, but I guess its gonna workout for a while so I figure I will try to fix this problem.

It sure sounds like hydraulics, due to the fact that when you pump the clutch everything works. I've had troubles with my Dodge hydraulics as it relates to my NV4500HD. I've replaced the clutch master cyl/slave cyl as a unit and they were always better - not good only better. Three units later I decided to go with South Bends HD system - problem solved. Mine now goes into all gears while stopped easily. It was a solution that worked well for me.

BTW in responce to your orignal question mine engages just before 1/2 way up.

Where does your clutch pedal sit when your foot is off the clutch? The reason I ask is I found that mine sat about an inch below the brake pedal. I found that the shaft the brake and clutch ride on had sliped out of the bracked that it rode in. We had a devil of a time getting it back in properly. Once we did it rode better and shifted properly.

Bob

My clutch engages about two inches from the pedal being all the way released. Which would make me think if it engaged that high up it should disengage that high as well if the clutch was going out.

Could it be air in the line?

Due to the fact that it works when you pump it either the master or the slave might be leaking. They are supposed to be a sealed unit but I've seen posts where some have replaced the slave cyl. Try doing a search and see what you can find.

Bob