Symptom: Clutch pedal fell to the floor while I was driving.

Cause: The slave cylinder piston wore a hole right through the clutch fork lever, and pierced through it!



How ridiculous, right? Now I have to drop the whole tranny just to replace this. I was thinking of maybe having a welder come by and weld that little scoop, but I don't know how long that would last, or what the metal is. That would save me from dropping the trans though. Man and I just had the engine out last month!

It is just steel - you could mig or TIG it and build up some material there. I used to grease mine with #2 axle grease but not with any regularity.

That is odd point of failure.

I never once greased it, but will be sure to now. While we are on the subject, what other points on the chassis do you guys add lubricant to? I need to go over the entire car, after going through this!

Will see if I can get a welder to come out and add some material there. That would save SO much time.

Better pic - didn't realize just how thick the fork was at that spot, amazing it went through all that material

Really bizarre. I've always used moly axle grease there and I don't remember it being anything but shiny upon disassembly. Maybe you got some sand up in that joint and it ground itself to death. It's worth a shot to weld it up and smooth it some. It can't really get any worse.

Corbin
'97 GSX dressed like a '95 ESi

Wow, I've never seen that one before... You def could have some material added so you don't have to drop the trans. Just make sure to remove the rubber cover so it doesn't melt. :) That's a lot of freakin wear. lol