Broken clutch release fork
 

After spending a couple days bleeding my clutch hydraulic line to solve a weak clutch pedal, I finally found the real problem. The clutch release fork is cracked right at the pivot point and broken. Granted the fork is 17 years old and my ACT pressure plate has stronger springs, but I have never had a release fork on a standard shift car actually crack and break. Has anyone else had this happen? Is there a stronger release fork available (Mazdaspeed??). The stock one looks like some kind of cast alloy. Most American cars have one made of stamped or pressed steel, not cast material, which can be more brittle.

it is common with 93-95 Fd's New 96+ Jspec tranny's come with a stronger fork. You can find a hardened fork traveling through the classfields or try calling Ray and Malloy Mazda, i believe he has some too.

All the new ones from Mazda are the stronger version, however it is impossible to tell the difference by looking at it. Still cast metal, just supposedly a stronger alloy.

I have spoken to Ray at Malloy Mazda on the phone a couple of times when ordering parts. Anyone know what his last name is?

^^^

His name is Ray Crowe.

stock FD clutch is 1200 pounds spring pressure.

typical ACT clutch 2600+ pounds spring pressure.

Exedy double disc 2200 pounds spring pressure but 2X the frictional surface so much more grab w less pedal.

there's no free lunch re rotary clutches unless you are willing to spend approx $1500 on a double disc.

the reason for needing all the pressure is our engines are so compact they have small flywheels w modest frictional surface... so up goes the spring pressure.

many of us (including me) have broken clutch forks. you didn't join an exclusive club.

hc

They aren't THAT expensive and it's been stated in previous threads to consider it with any clutch replacement, especially aftermarket.

:lol: :lol: :lol: I only laugh because mine broke this summer, too. It's an extremely, extremely common failure when running a heavier duty PP. :( And yes, Ray @ Malloy is a GREAT guy to deal with. :icon_tup: I actually just bought a very lightly used fork from crispyrx7 here on the forum for 40 dollars which had never been used with an aftermarket clutch. :) I was very close to buying one from Ray, though.

Also, thanks for the info on spring pressure howard! Makes me glad that I went with an Exedy twin disc clutch for yet another reason . ;)

Thanks for the info. Howard- I had no idea the spring presure increased that much for the ACT pressure plate. I had to go with it after I started modding the engine and spun the stock clutch due to the added torque. No wonder my left leg gets tired driving in stop and go traffic.

Damn im scared mine is gonna go soon lol :(

^ What clutch are you running? I was running an ACT when mine let go...:(

+1. It seems like its inevitable w/ stock (non-upgraded alloy) forks to crack, or even cleanly break as mine did. Call to Ray fixed that one...

lol ACT

I dont know the exact model since it came with the car when i bought it. But someone told me it could be a street/strip. Whatever model that is.

I know it is a silly question but can you replace the clutch fork without removing the trans?

no

Unless you are Houdini, no sir, you cannot. :P

I had that clutch as well. Although mine let go while running this one...

http://www.rx7store.net/product_p/zx3-hdr6.htm

broken clutch fork
 

Running ACT Xtreme(not MaXX Xtreme) pressure plate and ACT street disc.

If there was a market for these, I would weld up some reinforced cold-rolled steel pieces to make a more durable fork. With the dwindling number of FD surviving, I might sell one every couple years.

Been there too, replacing it isn't too bad, I did it on jack stands in my garage with a little help from a cheap transmission jack i bought at harbor freight years ago.

about how much are those forks? you guys got me thinking since Im pulling out the motor I should do some preventative maintenance and do the fork too. Supposedly I have an almost new "upgraded" clutch, gotta pull it out first to find out.

Yeah i def dont have that. Does that clutch make the clutch pedal stiff??

If so, i probably have the entry level ACT clutch because my clutch feels like stock. Or what stock "should" feel cause i never driven an FD with the stock clutch.

The pedal is probably what stock audi's have. Since i had an audi tt, the clutch feel is almost the same.

So am i in trouble?? lol

:lol: I'm not sure. :P I, as well, have never felt a stock RX-7 clutch. When I bought mine it had an ACT street/strip. If you don't have as heavy of a pressure plate then I'm sure you'll get some extra life out of your fork. :icon_tup:

clutch
 

ACT Xtreme pressure plate increases pedal feel about 25%. Upgraded clutch fork from Malloy Mazda is $87 plus $8 shipping. Ask to speak to Ray Crowe to get correct part number and mention you are on this RX-7 forum to get the discounted price. (price for STOCK clutch fork is over $114).

I have had three different types of disc/pressure plate combinations on the car. Stock (wore out twice), HD pp/disc from MazdaTrix with center hub springs, but without the flat fillis springs under the friction surface (touchy to engage, but no slippage) and the ACT Xtreme PP/street disc (good drivability and no slippage, harder pedal feel, but apparently a good way to break the clutch fork).
Talked to a couple FD owners who went radical and used solid center hub, 4-puck or 6-puck disc and HD PP and they liked them, except when starting out on a hill or stop and go traffic. The clutch is either fully engaged (rev engine and off you go, or stall the engine) or is not engaged- no gradual engagement and drivability is difficult.

If you drive like your grandmother stay with the stock setup. But since you are reading this we know your driving style is probably a little more aggressive.

The ACT street/strip (HD, not the ZX3) pedal feel is quite a bit stiffer than the stock clutch.

Okay, Ted. :lol: