New clutch install problem..

[tobluforu]

Ok, so I just put a new clutch, pressure plate, flywheel and used 75 tranny in my 72. When I attached the engine to the tranny, the clutch release fork from what I thought fit perfectly on the TO bearing via the sight hole at the tranny. Had minimal amount of play when I moved the throw out lever as well, not even a quarter of an inch. Put engine and tranny back in car, attached clutch cable, set free play, pressed clutch in at least 50 times and everything felt fine. Put oil in car (of course), went to start car for the first time, pressed clutch in one last time and pop goes the weasel. Car was still off the ground, checked clutch cable which was fine except now I have a little over an inch of play in the clutch throw-out lever. Did the clutch release fork just pop off the TO bearing, not sure how unless it wasn’t properly seated, or did the damn release fork break which I didn’t replace like an idiot, didn’t sound like a break? Also, the TO lever is now pointing toward the front of the car. Now what, yeah I know the whole damn engine and tranny has to come out? If the release fork didn't break, how did it pop off the TO bearing?

[rusnak]

I'm not familiar with that year, but is there a rollpin used to secure the TO fork? Can you just remove the starter and look in there with a mirror?

[tobluforu]

The fork and arm looks like this and from what I can tell the fork is held in place by a roll pin?

[rusnak]

The rollpin then would keep the shaft from dropping out of the trans case. I doubt the fork would slip, as the splines would not allow. I would probably try to get a look in there through the starter hole if possible.

[tobluforu]

I guess I'll drop it a tad, take starter out and have look. If it's a broken fork then I can only blame myself as I almost bought that damn piece 20 times during the past 4 months. So damn frustrating!

[rusnak]

Make sure it's not just a broken cable first, or clevis. The pedal will go clear to the floor.

[Flat6pac]

Probably broke the fork, its hard to see.Click here: Help, Check my story out, its not a hot link but its there if you look.
Bruce Click here: Help, 85 grinds going into gear - Pelican Parts Technical BBS

[tobluforu]

Originally Posted by rusnak

Make sure it's not just a broken cable first, or clevis. The pedal will go clear to the floor.

Cable is brand new and the way the arm is compared to what is was before, the fork either slipped off the TO bearing, somehow, or the fork broke.

[flatsixjunky]

I'm not familiar with your tranny but there is a part mounted behind the fork (901 trannyI believe), it looks like a washer but has a (+/- 1.5 inches) tab tilted at an angle that keeps pressure on the fork in order to force it stuck against the TO bearing. Maybe that's what's broken. But you're mounting a 915, I doubt this is it.

[flatsixjunky]

Thgis is the part I was talking about, Flat Spring for Release Arm, 911 (1970-71), which if broken would've done exactly what you're experiencing. unfortunately, like I said it is for 901 not 915 like yours. Sorry, please disregard my previous post.

[tobluforu]

How in the heck did the TO bearing pop off of the pressure plate, user error install, has anyone seen this happen before?

[Flat6pac]

If thats what the problem is, I ve never seen it. I still cant figure out how to get the TOB off the pressure plate the way the circlip snaps in, ofcourse, I never really wanted it off either.
Bruce

[rusnak]

Actually yes, I have heard of the TOB popping off of the pressure plate due to user error. It's not uncommon, and if this is what happened, then THANK YOUR LUCKY STARS, because usually this results in a horror story involving many $$. If you have a simple engine drop, and only have to re-install the TOB the right way, then you are living right. Stay lucky, my friend.

[tobluforu]

I just can't see how I installed it wrong as it's pretty straight forward. Maybe the snap ring wasn't seated properly? Heck I really don't know because when I looked in the sight hole I could see the TO bearing on the fork, but it was pulled out of the pressure plate. And yes thank god this happened before I even started the car. While it's out, again, I'm installing a new fork as well as I have it apart already.
Now that I think of it, when I torqued down the PP it did look like the TO was cock-eyed.

[KTL]

Agreed the install of the TOB is very simple. But the retaining ring can pop out of the groove if you don't get it seated all the way down in there. It's one of those things where it seems like it's in there fine, and then when you're fiddling with it and it pops into place, oh, now it's in. Sometimes you have to give it a jab with a blunted flatblade screwdriver to shove it down into the groove

[rusnak]

You can use an awl. I use an icepick.