clutch fork pivot ball: stronger replacement?
 

One of my clients has the act xd pressure plates on his t2. He has already broken two pivot balls. Does anyone make stronger ones or will this be something I'd have to get made from a concerned machinist in billet steel?

none that i know of and the ball is already steel so you would be more or less looking at titanium or cromoly.

but i have never had this issue after servicing the cars we build, usually the problem lies in sticky pivots. thoroughly clean the input shaft slide, throwout bearing, pivot, fork and regrease all the joints. a dirty/sticky throwout bearing is usually the cause of most failures because if it has resistance when sliding it will exert quite a bit more force on the pivots.

Is it a problem of lubrication on the ball? Or maybe it being worn out of round?

I replaced the pivot ball when I replaced the clutch couple of weeks ago. The new unit pivot ball had a thicker neck and head than the 1988 OEM one.

We shall see if it holds up or not.

I snapped one due to me being over zealous on cleaning the tranny before installing it and then not greasing it back up. I'm running a Act PP as well

I installed a new one and used wheel bearing grease all around it and on the fork contact points.

I've been fine for about 70k now