Clutch issues

Been having problems with my clutch for a few months now but adjusted it at the pedal and was fine again for abit but......last night i could get any gear and had no clutch. After inspection the slave cylinder pin had come all the way out so thats issue one, got a rebuild kit ariving on the 9th for that but....issue 2....after removing the pin and piston out of the slave i got drawn to the clutch fork.
I currently have a exedy paddle clutch and previous owners says it has a uprated clutch fork (the fork is blue if that helps) but i think its bent and this is the reason ive had to keep adjusting my pedal but before i start ripping the box off i wanted opinions off you guys

Heres a video of the play in my fork, if it works and a few pics but there abit crappy

https://i608.photobucket.com/albums/tt168/wocka_2009/157B0DDB-E245-46CD-AD87-BCA2E842292D-272-0000001329FD9DEB_zpsa4188685.mp4





I know the spring clip type thing isnt on but it kept coming off from wingling it, is it ment to be a tight strong fit or just to hold it in line? Anyway any help much apreciated

Thanks

Was my release bearing

How has that happened? badly fitted clutch or to heavy clutch?

Not a clue mate, maybe a cheap release bearing or old one was used?!? Previous owner had the paddle clutch fitted but so not sure what they put in. Im going to use a genuine one though, hopefully get one tomorow and check everything else before it goes back together

This not common then lol

Bad do mate, you have to take engine out?

Engine out? He's a real man lol

Haha real man! Just box off gaz, i think speed sensor took the longest to do. Was in there damn tight!!

So how hard is gearbox off ... Was gonna drop engine as thought it might be easier but might give this a try instead..

Theres a great thread i followed on gtir modifiers, go onto the help bit and its at the bottom of the page

Did you drop both box's together wocka?

No mate. We planned to but before we started taking transfer box apart we thought we would slide the box off as much as possible to try and get the fork and bearing out as that was most likely the problem so the box is left on the jack on the car, u have to remove the transfer box or as that thread says remove the diff as its to long to let u take the box off with it in place. Hope that makes sence lol

Yes mate i understood ....so with the fork out now can you see if its been uprated ?

Yeah mate, it has been uprated but theres a split across the welds so going to reweld it up later and i have a genuine release bearing on the way so be back together soon i hope

The 2 'bastard bolts' are much easier with the speed sensor removed if anyone is going to be removing the box soon

Wocka wrote:Theres a great thread i followed on gtir modifiers, go onto the help bit and its at the bottom of the page

excellent, i'm glad it was useful! it was me who wrote the 'how-to'  

for those interested it's in the 'how-to, guides & tutorials' section not help...
http://www.nissangtir.co.uk/forum/forum_posts.asp?TID=29352

good luck!

Adam

yes collapsed bearing would have damaged and weakened the fork so I would be very dubious of reusing it if I were you as it may well now have stress fractures due to more pressure being put on one side of it.

out of curiosity was it one of our forks as ours are normally all black.
could also be a dodgy input shaft bearing on the box that's caused the bearing to fail



adam
hope you don't mind but I have copied your how to on this forum as its a good write up you did there

Just spoke with the previous owner hu got the fork from you bob :/ would the fork not be ok after rewelding it up?

that must be a real old one as all ours for the last two years have been done black.

tbh I would not re-use it due to the state of the bearing and excess pressure being put on one of the forks could have weakened it severely, but its your cal at end of the day.

When its welded is it not welded with a flat plate over the ball section wich extends over the rest of the front face of the fork ?

no that's not sufficient enough Leighton as they need to be seam welded all the way round to strengthen the complete face not just the pivot point.
ive seen them before with heavy duty clutches and the fork face has folded up due to the excess pressure.
the pivot point in time will wear anyway but then youll just find that the clutch bite point will get lower and lower and theres nothing you can do about that other than change the fork itself.

with the above fork you can clearly see that its had excess pressure on one side due to a knackered bearing which has caused it to twist slightly and snap the weld so for that reason alone I definitely would not reuse it

GTI-R US wrote:adam
hope you don't mind but I have copied your how to on this forum as its a good write up you did there

no problem bob, happy to help those crazy enough to attempt it!  

mreguest wrote:

GTI-R US wrote:adam
hope you don't mind but I have copied your how to on this forum as its a good write up you did there

no problem bob, happy to help those crazy enough to attempt it!  

helped me with that write up only took 14 hours lol, we took it off with the diff and transfer box connected

So its welded at the front and down the sides also .... ive got a spare one so was going to reinforce it up what size plate do you use bob would 3mm be over kill .

yes 3mm is too much really, half that thickness is sufficient.
in all the forks weve done ive only heard of one other failiure and like this that was caused by a broken bearing which had bent the prong part of the fork out of shape

So when you plate it do you plate the front then fold the edges over then weld it on the edges if that makes sense ? Or just weld strips up the sides ? Sorry for the losts of questions bob i dont wanna chuff it up as the clutch fork cost me 12 quid delivered to me door  

yes just cut the plate slightly oversize then fold the edges then seam weld it. the centre part where the pivot sits you need to dome out so its a tight fit over the existing dome so if the pivot ball does wear through youll still be able to drive the car to get you back home and get a replacement fork fitted