Installing a clutch fork can sound like a complicated process but it can be a fairly easy job if you have the right tools and some expertise about cars and manual transmissions. Installing the clutch fork yourself is really important as it controls the gear shifting while the vehicle is in motion. It is imperative that this is installed correctly to avoid injury while driving. By doing this job yourself, you can also save you a lot of money that you would normally spend on labor if you were to take your vehicle to a professional. Follow this step-by-step guide and you will have your clutch fork installed in no time. A list of tools and materials required for the job is also given below.
Step 1 – Mount Your Vehicle on Jacks
The first step is to carefully mount your vehicle on several jack stands so that you lift it up enough for ease of work. There should be enough room to easily slide underneath your vehicle and enough room for maneuvering the 2x4 that will be used to help the transmission slide into place after you have installed the clutch fork.
Step 2 – Remove the Slave Cylinder
The slave cylinder is a small cylinder on the transmission and it pushes onto the clutch fork. Remove the bolts on the slave cylinder using your wrench and take the cylinder off. Do not push on the clutch pedal from the car after you have performed this step.
Step 3 - Remove Transmission
Follow correct procedure for your vehicle to remove transmission.
Step 4 – Insert Clutch Fork Ball into Bell-Housing
Now you will need to insert the clutch fork ball into the bell housing. After you do this, some part of the excess ball stud will be protruding fro the bell-housing. Don’t worry when you see this. This is normal and this is how your clutch fork installation process will work.
Step 5 – Secure the Throw-out Bearing
Take the throw-out bearing and install it onto the clutch fork and attach the fork on to the ball stud. Make sure when you do this by sliding it in with your fingers that the clutch fork is on the bearing and not in between the bearing and the transmission otherwise it will not work.
Step 6 – Cut the Ball Stud
Look at the ball stud in the bell-housing and make a mark on where it is protruding. After you’ve marked it accurately, use the fine tooth saw to cut the ball stud. After cutting it carefully, replace the ball stud back into the bell housing.
Step 7 – Attach the Clutch Fork
After you’ve secured the ball stud into the bell-housing, apply some grease on it and reattach the clutch fork to it. Slide the transmission back into place by placing the 2x4 between the transmission and the jack and bump it right in by using another piece of wood. It will wriggle in easily. Slide the transmission enough so that the throw-out bearing is lightly meeting the clutch fork. Replace and tighten all bolts that hold transmission to engine. Reattach the slave cylinder. Your job is done.