Hello list,
I recently requested help on how to best repair/upgrade my broken clutch
pin. I received numerous workable suggestions including: welding, replacing
the pin with a 3/8 bolt, adding a keyway, adding a through bolt and bolting
the fork to the shaft.
The best long term fix, IMHO, was to install a grade 8 bolt, threaded into
the shaft, on the opposite side of the clutch fork from the taper pin. With
a new taper pin already installed to insure alignment, I drilled a hole
through both the fork and cross shaft, at a 90 degree offset to the existing
taper pin hole. I tapped the shaft to a 5/16-18 thread and enlarged the
holes in the fork slightly to accomodate the bolt. I started with a
shouldered grade 8 bolt, but bought a die, $2.65, and threaded the shoulder,
as the shoulder was too long and would have messed up the threaded cross
shaft. Also, I drilled through the head of the bolt for a safety wire. The
bolt, with a grade 8 washer, is threaded into the shaft, and a nut and
locktite are used to secure the other end (redundant?).
Organizing the details of this repair was the most difficult task. Once I
knew what I wanted to do, it was reasonably easy. I had seen people use
taps and dies, but never done it myself. Tapping a hole is a little scary,
but it went just fine. This repair set me back over two weeks in getting
the car back on the road, because I need help (thanks again everyone), but
the actual repair took me about 3 hours of labor, since the tranny was
already on the bench. With both a new hardened taper pin and a 5/16 grade 8
bolt clamping the fork to the shaft I do not anticipate any clutch problems
due to a loose clutch fork.
BTW - To all who provided methods of removing the old fork from the shaft.
I had to cut the shaft to get the old parts out of the bellhousing. The old
fork is still on the shaft. I have been unable to remove it because the
taper pin hole in the shaft is all screwed up. For lack of a better
explaination, I believe this pin had been grinding for a while, maybe even
tightened up after it broke. The shaft, inside the fork, is a mess. When I
can locate a Dremmel or similar tool, I may be able to rescue the old fork.
Thanks everyone, for helping out.
Jack Brooks
1960 TR3A TS69032L
Jack I. Brooks Belco Technologies Corporation
Project Manager 7 Entin Road
201-560-8861 Parsippany, NJ 07054
Brooks@Belcotech.com http://www.Belcotech.com/
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