[spdbrake]

So the the "return " click, thats when you are releasing the pedal correct?

Is it still there once the engine is off? If so it may a good idea to listen outside the car while someone mashes the clutch repeatedly.
Have you looked at the slave cylinder? They can walk a bit in the clutch fork. Also see if the slave- rod- fork are in a straight line? side loads on the push rod shorten the life of the slave cylinder. Luckily they're cheap.