2003 Ion manual - I had a new clutch installed (slave, disc, flywheel, master cylinder) and now the shifting is VERY hard, and the pedal engages 1" above the floor. Even to start the car, I have to push pedal flat on the floor. I understand there is no adjustment, but why would it be? I had clutch replaced in 2015, and none of this was happening. I will check the cable /cliup at the pedal, but could it be anything else? The mechanic said he bled the clutch for over 45 minutes...

 

Bleed it another 45 minutes.
also, see if the bushings or the clutch pedal itself is worn causing slop

 

That's my plan - inspect the pedal and see if the link got pulled out and continue bleeding.

 

I am confused why it should take 45 minutes to bleed the system. It is a master cylinder 2.8 feet of tube, and the slave cylinder.

Check this: Can you lift the pedal up towards your driver seat? How far does it travel?
Where, (in relationship to what you remember of the proper clutch) does the pedal now sit and what about when you try to pull it up?

*Disclaimer, I have not owned nor driven a Saturn manual automobile.

 

The pedal sits where it sat before, but thye clutch "bites" about 1-2 inches above the floor instead in the middle of travel,

 

Obviously, you've never tried to bleed an Ion clutch. I personally spent days, even after I discovered and replaced a faulty (newly purchased) slave cylinder. It's not a job for the faint hearted.

 

They use a machine at the factory to bleed them.
Feel free to search the forum for people cursing ion hydraulic systems out.

Also feel free to purchase one, empty all the fluid, and proceed to fill and bleed

Apologies that sounds passive aggressive and although that is my nature, in this case it was not intended

 

Sounds like some here have not much experience with bleeding clutch systems. They can be a pain. Seen some take hours.
I learned that if you have someone tap on the lines while bleeding gets the bubbles to move around and works faster.