Shot clutch fork?

[G-Ride]

I blew a clutch slave the other day, replaced it before looking inside the bell housing and consequently blew the second one..
It looks pretty pitted and bent inwards causing the slave to overextend. I know it's supposed to have a small dimple for the slave rod to sit in. The first slave rod had worn through the plastic and pitted into the fork.

What are peoples thoughts? There is 100,000 tough Km on the Sachs Race Engineering Dual Mass clutch kit. I think it's probably time for a new one.

I'm thinking of extending the rod by 1/16 of an inch or so to get it down to the shop vs a flatbed.

[AudiTechS4]

looks normal

- - - Updated - - -

its steel . that plastic pushrod isnt going to hurt it

[G-Ride]

looks normal

- - - Updated - - -

its steel . that plastic pushrod isnt going to hurt it

Thanks, I do realize its steel, but it was metal on metal for quite a long time which has grooved it in.

[old guy]

It sure sounds similar to what happened to me from running a Sachs SS pressure plate and dual mass flywheel. After 80k miles of leg presses the clutch fork finally gave out.





Along with your new clutch kit you are going to want to replace part numbers 5, 6, 7 and 8.

[G-Ride]

It sure sounds similar to what happened to me from running a Sachs SS pressure plate and dual mass flywheel. After 80k miles of leg presses the clutch fork finally gave out.





Along with your new clutch kit you are going to want to replace part numbers 5, 6, 7 and 8.

Thanks for chiming in Old Guy, I tried to swing the bore scope the other way to have a look at the clutch fork all the way down but it wasn't working out.

Have you moved to a single mass clutch?

I've wanted to avoid single mass flywheels for quite some time, but given the amount of torque that is produced on E85, i'll probably have to consider it. The clutch/flywheel was vibrating when letting off 1st slowly from a standstill which made me think the flywheel had either separated or was royally stuffed. A few days later the first slave went, then I over night shipped a second one from Audi at Australian prices ($200 for a Sachs/Audi). Bled that in took it for a drive, however it still wasn't feeling great and the disengagement was an inch off. Pulled the car back into my drive way, and the last pedal press before I turned the ignition off the slave blew again. It'll be an expensive exercise..

[old guy]

If your clutch engagement point has dropped to the floor that sure sounds like a bent fork or broken pivot block. Plus it explains the blown slave cylinder. I did the same thing. Pushed the end right out of the cylinder.

I am currently running a Valeo single mass clutch kit. I have about 60k miles on it now and I am totally happy with it. I was pretty worried when I added the F21 as to whether it would work out but so far it has been fine.

With that being said I think you may be putting out torque that is a bit beyond what it's capable of holding. A single mass kit should work OK for you but I think something rated a bit higher would be more appropriate.

[G-Ride]

If your clutch engagement point has dropped to the floor that sure sounds like a bent fork or broken pivot block. Plus it explains the blown slave cylinder. I did the same thing. Pushed the end right out of the cylinder.

I am currently running a Valeo single mass clutch kit. I have about 60k miles on it now and I am totally happy with it. I was pretty worried when I added the F21 as to whether it would work out but so far it has been fine.

With that being said I think you may be putting out torque that is a bit beyond what it's capable of holding. A single mass kit should work OK for you but I think something rated a bit higher would be more appropriate.

The clutch was certainly rated for it, had a max transmissible torque rating of 420nm/310 ft-lb. It's never slipped or let go, its been a beautiful and very smooth clutch setup. They do have a single mass version of it that I'll probably look at.

http://www.sachsperformance.com/Sach...-Kit::101.html

[old guy]

I was referring to the Valeo kit not being adequate for your setup.

[G-Ride]

I was referring to the Valeo kit not being adequate for your setup.

Ahh sure, missed that. Do you notice much vibration with the single mass vs the dual mass? I've always liked keeping the refinement there to be honest.
I drove a car a few years back with an ECS 240mm single mass clutch kit and it was horrible. The engagement and overall feel was nasty.

[old guy]

Ahh sure, missed that. Do you notice much vibration with the single mass vs the dual mass? I've always liked keeping the refinement there to be honest.
I drove a car a few years back with an ECS 240mm single mass clutch kit and it was horrible. The engagement and overall feel was nasty.

I believe the ECS kit contained a lightweight single mass flywheel. As long as you have a full weight single mass flywheel you will not experience all the low speed gear chatter that comes with a lightweight flywheel. Here were my impressions after I installed the Valeo kit with a single mass flywheel: Clicky click®

[Human Garbage]

I say the fork looks like old guy's pictures when you pull it out. They are notorious for bending and cracking. I had the same thing you are experiencing happen on my Jetta. Blew a slave before pulling the trans only to find the fork pretzel'd. I'd recommend reinforcing your new fork. I took some .062" steel plate and my TIG and beefed it up good. No photos sorry, it went back in still hot from the welder as I had to make it to work the next morning...

[G-Ride]

I say the fork looks like old guy's pictures when you pull it out. They are notorious for bending and cracking. I had the same thing you are experiencing happen on my Jetta. Blew a slave before pulling the trans only to find the fork pretzel'd. I'd recommend reinforcing your new fork. I took some .062" steel plate and my TIG and beefed it up good. No photos sorry, it went back in still hot from the welder as I had to make it to work the next morning...

Yeah, I've seen something similar from UROTuning
http://www.urotuning.com/Clutch-Leve...erformance.htm

Their symptoms of a bad clutch fork pretty much nail my experience before blowing a couple of slaves.