Replace clutch fork bearings/sleeves

matara Custom Title Time!

1,342 posts · joined Aug 2002 · 16 Jun 2009, 2:26 pm

#718803

I'm doing an IRS conversion on a splitty, and the AT IRS g/box I've got didn't have a clutch lever arm installed. I've got an arm, and the lever, and an install kit. The install kit has a bush, a sprint and two little rubber concertina seals and a circlip.

How do I go about installing it all?

Thanks

Steve

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 · 16 Jun 2009, 5:44 pm

#718846

put one circlip and washer onto the shaft
apply your favourite lube on the end and insert it.
I then lube the shaft and inside the bushes and seals,
and slide the bush and seals over the shaft and into the case,
while aligning the hole in the bush for the locating bolt.
Once the bush is locked by the bolt,
the steel protector cup can go on before the spring,
then spring,
then arm/lever.

I do not preload the spring until the arm/lever is started on the spline,
then i preload the spring to hook over the arm,(large round philips screw driver as a lever)
and then the last circlip goes on.

westi wrote:That's mad Alan.

cnfabo Custom Title Time!

1,353 posts · joined Apr 2008 · 16 Jun 2009, 8:16 pm

#718892

and make sure that bush slips on the shaft nice and easy, spins easy. if it doesnt i wet sanded the inside of the bush till it fit over the shaft.

the first time i tried installing this i got the bush stuck on the shaft then couldnt get it off, and couldnnt get the fork out of the bellhousing. i had to grind it in half to get it out. yep ha ha, i learnt the hard way.

and to line the bush up with the bolt that holds it in place. i first put the bush in and marked it with a marker, because u cant see it line up when the shaft is in the bush.. yipeeee...have fun. and make sure u have the right clutch cable arm, so the cable doesnt rub on the end of the bowden tube..

matara Custom Title Time!

1,342 posts · joined Aug 2002 · 16 Jun 2009, 10:08 pm

#718925

I think I've discovered my problem. My IRS gearbox clutch shaft seems to be a lot thicker (20mm diameter) than a regular 61-72 shaft would be.

I think I have the later throwout bearing, the one with the spring retainers rather than the little wire clips.

The kit I have says 61-72, and the stamping on my gearbox dates it as a 72 AT box, but I think there must be a kit with a bigger bush for a 72-> box.

I'll see if I can locate a late model kit.

Thanks

Steve

vw54 Administrator Always Waiting 4 Friday

16,723 posts · joined Aug 2002 · 17 Jun 2009, 5:47 am

#718961

steve there r different size bushes you will have to do a bit of test n trail fit to get it right

I read it on FACEBOOK so it must be true

http://forums.aussieveedubbers.com/viewtopic.php?tid=91278&page=1#pid848630

http://forums.aussieveedubbers.com/viewtopic.php?tid=63561&page=1#pid624099

http://forums.aussieveedubbers.com/viewtopic.php?tid=4832&page=1#pid452603

http://forums.aussieveedubbers.com/viewtopic.php?tid=60650&page=1#pid574409