Alright, update with the Kia, more updates to come. My GF is a downshifter, unfortunately, although she's now changed her mind. Me and one of my mechanic buddies just spent 10 straight hours in 100 degree texas heat changing the fucking clutch on that pile of shit, and the cause :
A throwout bearing made mostly of ... plastic? The Flywheel and Clutch themselves were 100% perfect. The god-damned TOB came apart, what was left was three distinct pieces, the rest of it dissolved inside the clutch housing. The plastic inner part of the TOB disintegrated, letting the metal rings completely wear down the metal splines that used to be on the transmission housing, and it caused the fork to jump, breaking the slave cylinder, and also seriously fubaring the pressure plate.
The replacement TOB that we got from SouthWest Kia of Dallas is apparently the only one, and indeed the new one is also made of plastic. Although the new one fit and held the fork, which was banged up but not bent, the splines on that connector being worn off mean that it's now a bit loose. It's probably going to fail again soon. The parts/service manager at the Kia dealership says that tons of the early 'JB' Rios have failing manual trannies at well under 100k miles. The real kicker? The god damned motherfucking transmission now has a bunch of spiderweb cracks in the housing facing the driver's side wheel well, and they go from top to bottom. Ughhhhhh. So either the TOB is gonna fail again soon, or the tranny housing is gonna shatter.
So, bottom line is that a car that inexplicably has a shit quality TOB can indeed cause catastrophic damage, and yes, going to neutral and being on the clutch as little as possible with that scenario is a fucking fine idea.
Perhaps/probably most quality cars and probably all more classic cars have beefier TOBs that aren't such trash.
/rant off. I'm just pissed that this little piece of plastic garbage just cost me about $800 alone today, and unless we dump this POS soon, it's gonna be a full transmission replacement pretty quickly.