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Old 12-04-2012, 07:37 PM   #1 (permalink)
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Default clutch fork replacement

hey guys, My clutch fork decided to snap in half a few days ago, I ordered a new one off of 3sx and i was wondering if anyone could give me a step by step on how to do this. I was able to do head gaskets with a step by step so do you think this job would be of the same difficulty? basically i just want to know how to replace the old shift fork with the new one. Any help would be greatly appreciated.

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Old 12-05-2012, 04:39 PM   #2 (permalink)
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Default Re: clutch fork replacement

Pull the transmission, pop out the old fork from the ball retainer, grease the ball and pop in the new fork. Grease the friction points on the fork. Install the tranmsission.
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Old 12-05-2012, 05:33 PM   #3 (permalink)
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Default Re: clutch fork replacement

When in doubt I go to youtube. It is surprising how many videos they have on working on our cars.
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Old 12-05-2012, 07:21 PM   #4 (permalink)
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Default Re: clutch fork replacement

Beau forgot one tiny little detail- Make sure the ball is fastened TIGHTLY to the bell housing. I have found a number of them loose.

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Old 12-05-2012, 07:22 PM   #5 (permalink)
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Default Re: clutch fork replacement

The best source is the factory maintenance and rebuild manuals. You can download them for free on the 3sx website or buy one on CD rom or on paper.
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Old 12-05-2012, 08:23 PM   #6 (permalink)
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Default Re: clutch fork replacement

sweet. thanks for all the help guys, the main part i will be needing help with is dropping the trans, but ill check out the manual and on youtube, hopefully i can peoce it all together, thanks again.
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Old 12-09-2012, 09:43 AM   #7 (permalink)
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Default Re: clutch fork replacement

A couple of other things to check when you have it apart.

Make sure the pivot ball is smooth and does not have any cracks or scratches. Damage to the ball can cause premature failure of the fork. This is usually where the fork breaks. Make sure you lightly grease it.

Make sure the fork is at the half way position within the boot window. Not often, but sometimes the ball has to be shimmed.

Regrease the tip of the slave cylinder shaft.

Check clutch pedal adjustment to make sure the slave cylinder can self adjust.

And don't put the disc in backwards or put the flywheel back on without the dust plate in place first.

I am assuming if you have it apart, you are likely to change the clutch and resurface or replace the flywheel.
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Old 01-21-2013, 01:41 PM   #8 (permalink)
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Default Re: clutch fork replacement

hey everyone, so i thought id keep you updated on the situation.
I dropped the trans and replaced the clutch fork with one from 3sx. After putting everything back together and bleeding the clutch the car started up just fine, the problem is when i let out the clutch about halfway, I get this scraping noise which seems to be the clutch fork rubbing against the clutch. I verified this by touching the fork while the sound was happening and i could feel the fork vibrating against something. sooo does anyone have any idea as to why or how this could be happening, I'm not sure where i went wrong, i did everything according to the repair manual, but obviously something isnt right, any advice would be greatly appreciated and thanks to everyone on here who helped me get this far.
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Old 01-21-2013, 07:52 PM   #9 (permalink)
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Default Re: clutch fork replacement

Quote:
Originally Posted by 3000-ieDUDE View Post
hey everyone, so i thought id keep you updated on the situation.
I dropped the trans and replaced the clutch fork with one from 3sx. After putting everything back together and bleeding the clutch the car started up just fine, the problem is when i let out the clutch about halfway, I get this scraping noise which seems to be the clutch fork rubbing against the clutch. I verified this by touching the fork while the sound was happening and i could feel the fork vibrating against something. sooo does anyone have any idea as to why or how this could be happening, I'm not sure where i went wrong, i did everything according to the repair manual, but obviously something isnt right, any advice would be greatly appreciated and thanks to everyone on here who helped me get this far.
If you checked the clutch pedal travel (I do not recommend following the manual when adjusting. The attached method insures proper travel for the slave cylinder), then it can only be a few things. Installed the pressure plate backwards, over-torqued the pressure plate bolts, or the fork slid off the throw out bearing. Is the fork sitting in the middle of the boot window? Is there any play in the fork when the slave cylinder is not installed?

https://www.youtube.com/watch?v=vYJxQyjIhUw
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Old 01-22-2013, 01:27 AM   #10 (permalink)
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Default Re: clutch fork replacement

iedude- I think you overlooked the throwout bearing when you had everything apart.

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