in that case it is very strange.
you are doing everything right and the fork is right where it should be.
i came across a failing slave cylinder when the fork has broken, and the cylinder travel was longer then it should be.
in your case, it looks like the fork is not reaching its full travel.
assuming you are using the correct part (and it looks like it), it looks like something is wrong with the fork and throw out bearing. i know it doesn't make sens as it use to work fine before the slave cylinder failed, but maybe the hydraulic fluid in the trans case, cause the bearing to seize on the Guide Sleeve.
if it was me, i would probably drop the transmission to see what going on in there, and give it a good clean. it might be the time for a new clutch.
at 140 you should be at your second clutch replacement.
however, i'm not a pro, so maybe you should wait for one of them to chime in.
boxster S
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