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Old 05-18-2012, 08:10 AM
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Slave Cylinder / Clutch Fork Alignment

I have a little story that might be of help to someone some day. Or then again, maybe not. LOL.

After replacing my transmission mount, I started hearing a knock when I was pressing the clutch pedal in. Turns out the new mount is taller than the old one, and the knock was from the clutch fork snapping against the floor

Crawling under the car and watching, I could see it was due to "slave cylinder / clutch fork" misalignement. Refer to the picture below and keep in mind the slave cylinder axis was lower than the fork fore and aft movement axis. As the slave started to push the clutch fork back, the side pressure would increase and push the fork up against the floor (actually the transmission tunnel flange).

The spring added to the issue as it held back the fork for a while, and then as the angle got steeper, the fork would suddenly fly up against the floor making the click or knock.

The slave cylinder bracket had a tab to help align the assembly, but for whatever reason, the alignment was out on my car. Luckily, it wasn't terribly precise, so I was able to rotate the bracket and bring the cylinder quite a bit higher up. In fact, if anything, the cylinder axis is now higher than it has to be by a tiny bit. With the spring, the whole thing now works smooth and is quite clear of the floor. The problem is gone... I hope. A road test will be the proof in the pudding.

Just hope there's enough clearance for the engine torque (sway space). I think there is, but barely.

ps: This is a Ford clutch fork. Pivot is an L-Bracket riveted inside a Lakewood Bellhousing. Not sure if this mess could happen with a ball mounted fork.

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