Old release fork broke after new clutch installed?

[wesleyc]

When I took my shaft out it came too easy due to lost or ground down needle bearings. I found no plastic cap on end of shaft when I went to pull it.

[sand_man]

Too late now, but I wonder if there were signs if imminent failure on this part of the housing: spider cracks, slight fracturing, etc.? Something you (or me) would not have even thought to check.

[wesleyc]

After talking to Darin fister and comparing pics and determined shaft wasn't in all the way. Beginners mistake costing me dearly!!

[iamtheari]

How were you able to determine that? Do you have a picture to show how it shouldn't look or how it should? I'm getting close to that step myself and would rather cheer you on from the sidelines than join you in the repair process. Sorry to hear about it!

[bazar01]

I was wondering how can that happen.

How were you able to put the bracket and cap back on and lock it with the hex head bolt if the shaft is not all the way into the second ear on the inside?

[bazar01]

I may be wrong but there is no way you can put the bracket (#2) and hex bolt (#1) back on if the shaft is not all the way in to the second inner ear.

[wesleyc]

Part 3 ( cap ). I lost and didn't realize it. I pushed the shaft and bearing all the way in but through jostling around the clutch and engine the bearing eased its way flush with retainer part (2). The far side bearing did seat in the correct position at first.

[Jeff Alton]

Though not the problem the OP suffered, we have seen 2 broken forks in the last year....

[wesleyc]

I forgot to pull the old bearing out of far side bearing. Beginners mistake that cost dearly!

[bazar01]

Originally Posted by wesleyc

I forgot to pull the old bearing out of far side bearing. Beginners mistake that cost dearly!

Wow.

I still cannot imagine how you were able to install part #2 and hex bolt with cross shaft sticking out that far equal to the needle bearing width.

Well, I really hope you get it fixed.

[wesleyc]

Baza01. I am bound and determined to redeem myself !! The car WILL run correctly!!!

[TMc993]

Originally Posted by wesleyc

Baza01. I am bound and determined to redeem myself !! The car WILL run correctly!!!

There's no need for concern about redemption...We've all taken on projects that didn't pan out....It's part of working on your car...

Once, many years ago, a friend and I were finishing up re-installing a just rebuilt 402 cu in V8 in his 1949 Olds street rod. I was bolting on the valve covers and one of the bolts slipped out of my hand and flew over the top of the engine. We looked for it for a few minutes and decided it had rolled under the workbench in the shop.

I found another bolt, finished up the valve covers, and we started the car. The engine started immediately and ran well. Then, suddenly there was a brief rattling racket and then the engine started to miss badly.

Yep, the bolt had fallen into one of the carburetors, got sucked into the engine when the engine was started and bent two valves, among other things. Sadly, if we had just bothered to just look into the top of the carburetors, we probably would have seen the bolt laying on the throttle plate...Live and learn.

[bazar01]

Originally Posted by wesleyc

Baza01. I am bound and determined to redeem myself !! The car WILL run correctly!!!

No doubt about that. Good luck man! Hope you don't spend a lot though.
We all have been through some kind of set back doing our own fixes.

[wesleyc]

Thanks guys. Brain farts happen I guess. On the upside. My first engine drop took 15 hours. Second time 7. and the spiritual opportunity... Priceless

[RichPugh]

Edit. I didnt see your reply regarding the inner bearing issue. Hope all goes back together well.

[wesleyc]

Simple mistake Rich. I pulled the trans. Saw the far side or ( inner) bearing stuck in trans. Instead of pulling it out right then. I began putting new bearings on shaft. Laid shaft on table with new bearings on it. Went to bed. Got up next morning and mother-in-law went to hospital and died. Didn't touch project for 5 day's. Came back. Slid trans on. Put newly bearinged shaft through fork ( I thought ) put everything together to test drive... And that's your recipe for disaster.

[Nine9six]

Originally Posted by wesleyc

Simple mistake Rich. I pulled the trans. Saw the far side or ( inner) bearing stuck in trans. Instead of pulling it out right then. I began putting new bearings on shaft. Laid shaft on table with new bearings on it. Went to bed. Got up next morning and mother-in-law went to hospital and died. Didn't touch project for 5 day's. Came back. Slid trans on. Put newly bearinged shaft through fork ( I thought ) put everything together to test drive... And that's your recipe for disaster.

Yep. That'll do it...Seems like you had your hands full.

[wesleyc]

Yep. Livin the " porsche repair dream " alright. Luckily rennsport in Tulsa is going correct my mistake.

[iamtheari]

I hate to profit from your misfortune, but after reading about your experience I noticed that the outer race of the needle bearing on my transmission was also still there. I was able to push it out and the new bearing went in fine. So at least one person other than you has taken some benefit from your unfortunate experience. I hope you come away from it without too much expense or delay! Good luck with Rennsport.

[wesleyc]

Thanks iamtheari. That makes me feel a bit better. It'll be $250 and another week without the car and of course a bunch more work.