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Assuming that everything was installed OK and pedal adjusted - I would still suspect a hydraulic issue. Did you verify that you had plenty of brake fluid in the master cylinder? May need to flush that old stuff and with fresh fluid, then rebleed the whole works.
Sounds like the clutch is refusing to disengage. When you had it apart - how did the friction material look? Any shiny spots, glazing? Did you take a look at the springs on the disc (assuming it is a sprung disc) - did they get distorted or even popped out? How amount the flywheel and pressure plate - did they look OK? Usually good practice to use new hardware (bolts) when you replace the clutch - heat and use over time will weaken them. If one of the bolts backed off - it could cause a stuck clutch. I'm not sure about what clutch you have - but some will jam up if installed backwards.
From your description - sounds like a bolt or spring popped loose (car running fine, then suddenly clutch quits). You'll probably have to pull it apart and look at it closely. Check all the bolts - as one could be missing or the head snapped off of it.
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2002 Corolla S, 1.8L 1ZZ-FE VVT-i
2003 Matrix XRS, 1.8L 2ZZ-GE, VVTL-i (RIP)
2009 Matrix XRS, 2.4L 2AZ-FE VVT-i
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