I had the
exact same symptoms as you with my previous FR-S. I had to replace the factory TOB ~60k miles because it started squealing and was getting worse. Since the transmission was being dropped, guess what I ended up installing as well...
- ACT SB7-HDSS Kit
- Velox (Verus) Forged Clutch Fork
- Velox (Verus) Billet Clutch Fork Pivot
- Redline MT90 Fluid


Was fine until ~6k miles in and then I started experiencing issues:
- Could never get it into gear from a stop. (Sometimes I would have to throw it into 3rd in order to unlock 1st, and even third is sometimes locked out)
- No issues while car is in motion.
- Keeping clutch depressed while rolling to a stop was the only way I can ensure that I can get it into gear when it was time to move again.
- Only happens when car is warmed up. Feels fine when car is cold.
Bled the clutch fluid, replaced the slave cylinder ...but in the end, I could never figure out why before moving on to my current BRZ.
My guess? ACT quality control needs improvement.
Another forum member went from an ACT kit
back to stock and all his problems went away.
EDIT: @
EndlessAzure got to the thread first.