Bent clutch fork pin. How did this happen?

[Jason]

Suddenly today I was having occasional problems putting the car in gear. The clutch wasn't quite disengaging all the way. So I started looking for what could be wrong and found....

20180226_202532.jpg

Any idea how that happened? Am I correct that I have to remove the transmission to replace the clutch fork?

I tried looking inside the bell housing with a snake camera and didn't notice anything that looked scary. This is the best picture I could get of the throwout bearing.

WIN_20180226_21_06_40_Pro.jpg

[dn010]

Looks like the slave cylinder might not be installed correctly causing the pin to be misaligned. The hole in the pin is now worn too large for the fork and it’s sitting sideways. Did a bolt come loose from the slave cylinder?


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[PJ Grady Inc.]

Suddenly today I was having occasional problems putting the car in gear. The clutch wasn't quite disengaging all the way. So I started looking for what could be wrong and found....

20180226_202532.jpg

Any idea how that happened? Am I correct that I have to remove the transmission to replace the clutch fork?

I tried looking inside the bell housing with a snake camera and didn't notice anything that looked scary. This is the best picture I could get of the throwout bearing.

WIN_20180226_21_06_40_Pro.jpg

Yes you would have to R&R the transaxle to service the fork. It looks like the T/O bearing is out of position causing the fork to twist. This normally only can happen if the bearing comes out of position while installing the transmission. We always pull the fork pin into the slave cylinder and lock in position with a tiewrap to avoid that possibilty when installing a transaxle. Did you have a noisy throw out bearing before this happened? If the transmission has not recently been removed my guess is catrastophic failure of the bearing which could mean the clutch tube is also damaged. If that's the case you will also need to split the cases. The fork and tube are listed as NLA at DMCH but we have availability should you need one or both along with anything related.
Rob Grady

[Jason]

Well, here is what I found...
20180228_010650.jpg20180228_010700.jpg20180228_010743.jpg20180228_010751.jpg

The throwout bearing was about 5 years / 30K miles old. There doesn't seem to be enough bits there to make a working one.

The transmission itself seems ok.

[Josh]

That is a strange failure. Good to hear your transmission itself appears to be OK.
Looks like you also need to do the rear main seal.

[Nicholas R]

Looks like you also need to do the rear main seal.

Seconded!

I would imagine you'll be able to get away with a new throw-out bearing if you can sort out the clutch fork. If the pin on the fork is bent or wallowed out, you'll probably need to come up with a way to fix/replace it.

[Josh]

I believe Ed is manufacturing clutch forks for a reasonable price.

[Jason]

Looks like you also need to do the rear main seal.

That goop is all gear oil. Despite having the seal replaced and the input shaft sleeved that transmission likes to leak from the input shaft. I've kind of given up on it for now. Other than making the inside of the bell housing look nasty and some occasional drips on the garage floor it doesn't seem to be causing any problems.

[dn010]

With that amount of oil all around I am surprised none has gotten onto your clutch disc!

[PJ Grady Inc.]

That goop is all gear oil. Despite having the seal replaced and the input shaft sleeved that transmission likes to leak from the input shaft. I've kind of given up on it for now. Other than making the inside of the bell housing look nasty and some occasional drips on the garage floor it doesn't seem to be causing any problems.

The input shaft rarely leaks oil and when it does a proper size sleeve should take care of any grooving. While the transmission is out you really should try to fix that leak. Perhaps that took out your throwout bearing as I've never seen one fail at the 30K mark. You may need to replace the primary shaft to solve the leak or try another sleeve. Did you fit a new NOS seal when the sleeve was installed?
Rob