Follow-up
 

OK heres one for you-

He drove the car again with everything adjusted and 1/4 mile later the car wont shift. The problem?

The input shaft most likely has a slight twist. He installed another 4 speed and no problem. Talked to a trans guy I know and he said either the air-gap between the pressure plate and the clutch disk was a problem- or the input shaft.

The shaft was used and it probably is just off a hair. The test will be to install a used 10 spline clutch disk and check the motion forward back and axially- should have some side to side motion.

New rule- All used front shafts get a clutch demo.

Thanks for everyone's help- Just want to share this in case it might help someone.

Scorp