clutch release fork problems, more DAPO issues Options

[mightyohm]

Hey guys, I need some help with a release fork/pivot shim issue I have run into.

I am working on reinstalling my transmission after my lost driveshaft incident.

I have a new clutch release fork that I installed, and I noticed that when I stuck the transmission back on the engine, the fork doesn't have more than a few mm of free play before it hits the transmission housing. So I think hmmm and I pull it back apart.

Then I think back to the last time I did this, I put in a new cup in the old throwout arm. At that time I noticed the ball cup stuck way out of the fork and I had to actually trim it down to fit. I thought it was weird but blamed Brad on giving me crap parts (just kidding Brad). I even took a picture, shown below.

[SirAndy]

What I want to know is, can I get by with less than 20mm travel of the clutch fork?

ok, here's what you have to do. this might sound strange, but it has been done and works.
just don't tell anyone that i told you. (IMG:style_emoticons/default/wink.gif)

take the clutch-fork, put it in the vise and use a BFH and bend it.
make sure you bend it about 1" or so *after* the cup part, on the thin part of the arm.
that will give you more clearance on the tranny case and you'll get enough throw at the fork.

trust me, it'll work!
(IMG:style_emoticons/default/smash.gif) Andy