Car nightmare - Toyota GR86, 86, FR-S and Subaru BRZ Forum & Owners Community

ichitaka05 · 09-02-2011, 02:40 AM

Left is new one, right is old one. Yes, that old fork is broken in 2 pieces.

K, it's gonna be hellova long post, so bare with me on this bitching.

2 weeks ago, I was noticing I have hard time shifting the gear. So checked under the hood and see what's wrong w friend. We thought clutch master cylinder went bad (cuz I saw some wet spots), so I called around all the auto parts store and if they have em... sadly no one in the valley had it so I had to special order it (only took 1 day to deliver).

Saturday part came in, so install the clutch master cylinder and start bleeding it, I notice that fluid is leaking from clutch slave cylinder too. Tell myself "FML moment #1" and called around to see any shop have slave cylinder. Lucky enough Pep Boys which was 3x more than Auto Zone was asking for was the only one that had it (I didn't want to wait til Monday), so went there and got the slave cylinder.

After buy damn expensive slave cylinder, start installing it. When we start to bleed it, we see fluids coming out between the rubber and the metal stick thing... "FML moment #2". Slave cylinder they gave me was defect. Try to call them back... but they've already closed for Saturday (WTF 8pm on weekend? WTF?!?)

Sunday, called them and see if they have another slave cylinder, but they didn't have it at the store... correction, closest store was next state (Idaho!). They told me that it's gonna take 5~7 days to ship it here. Fuck that, I can't wait that long to get it, so got my money back. Damn expensive for nothing!

Monday, on lunch break try to head to Auto Zone to special order in slave cylinder, but I got caught up on all the files and I didn't have time to go to Auto Zone before noon (if you special order before noon, it'll come next day 3pm).

Tuesday, went to Auto Zone and special order the slave cylinder and they told me that it's be here Wednesday 3pm. Cool!

Wednesday, call Auto Zone 4ish to see if the part I've order have came in. After 10 plus mins put it on hold they finally have it. Got the part and start installing the slave cylinder. After everything is gone, still not working properly... I was telling myself "WTF, why isn't working?" looking closely at the transmission fork (which slave cylinder pushes), it wasn't pretty and it moves around badly... so I've put flashlight inside to see what's up w it just to see 2 huge cracks on the fork! "FML moment #3".

Start calling up all the shops again if they have it. None of em had it, so I had to call the dealers to see if they have that fork. Call 4 dealers and none of em had it. Call one small Subaru dealer and amazingly enough they had it... but sadly that dealer is over 30min drive and they told me that they gonna close that parts department at 6pm... and it was 5:45pm. Lucky enough my friend's fiance live 5mins away from that dealer, she was nice enough to go there and pick it up for me.

Today, I've pulled off drive shaft, and everything that gets in the way of separate engine and tranny. After 7 hrs of sweat, scream, swearing, and all those things. Friend and I have pulled off the trans fork & that pic at the top is it.

Tomorrow, I'll be installing everything back together again. Seriously, how in the fuck you break a trans fork? that thing is pretty hard. I don't slam on my clutch... Ah whatever, I'm just glad this thing is over with

WingsofWar · 09-02-2011, 03:23 AM

oh god, i have the same engine and transmission on my legacy. I hope my fork doesnt go out on me. Iv been having some clutch engagement chattering problems, like when i get into gear and go, the car likes to lunge back and fourth like the clutch is grabbing then not grabing then grabbing again about 3 times before it gets smooth. I gotta bring the revs up higher than im comfortable with to get smoother engagement.

ichitaka05 · 09-02-2011, 04:04 AM

Quote:

Originally Posted by WingsofWar

oh god, i have the same engine and transmission on my legacy. I hope my fork doesnt go out on me. Iv been having some clutch engagement chattering problems, like when i get into gear and go, the car likes to lunge back and fourth like the clutch is grabbing then not grabing then grabbing again about 3 times before it gets smooth. I gotta bring the revs up higher than im comfortable with to get smoother engagement.

That might be more of clutch disc/pressure plate problem. When's last time you replace the clutch?

Giccin · 09-02-2011, 05:06 AM

That sounds terrible. I have a hard time doing tire rotations and oil changes. LOL WHERE ARE MY RHINO RAMPS!!?!

Glad it worked out Ichisan

WingsofWar · 09-02-2011, 05:48 AM

Quote:

Originally Posted by ichitaka05

That might be more of clutch disc/pressure plate problem. When's last time you replace the clutch?

its been a while, im thinking that its a clutch/plate issue also by the way it behaves but you can never be to sure. Iv had decently new throwout bearings shit on me after a day in traffic. I just hope whatever my issue is, its not anything thats broken.

ichitaka05 · 09-02-2011, 11:23 AM

Quote:

Originally Posted by Giccin

That sounds terrible. I have a hard time doing tire rotations and oil changes. LOL WHERE ARE MY RHINO RAMPS!!?!

Glad it worked out Ichisan

LOL you should of seen my friend's fiance she got down on the ground and help me out too. Here's the pic

Quote:

Originally Posted by WingsofWar

its been a while, im thinking that its a clutch/plate issue also by the way it behaves but you can never be to sure. Iv had decently new throwout bearings shit on me after a day in traffic. I just hope whatever my issue is, its not anything thats broken.

Amen to that. Seriously, it wasn't fun at all. If my friends weren't there to help me out/keep me entertained, I would put c4 and blew it up.

I told my friends that, I had this car for 5 yrs and out of that, 3 yrs I had to separate engine & tranny. Next time, if tranny have a problem, I gonna swap it out w 6sp STI tranny

Want.FR-S · 09-02-2011, 01:18 PM

Quote:

Originally Posted by ichitaka05

LOL you should of seen my friend's fiance she got down on the ground and help me out too. Here's the pic

Amen to that. Seriously, it wasn't fun at all. If my friends weren't there to help me out/keep me entertained, I would put c4 and blew it up.

I told my friends that, I had this car for 5 yrs and out of that, 3 yrs I had to separate engine & tranny. Next time, if tranny have a problem, I gonna swap it out w 6sp STI tranny

And she is the nice one who picked up the part for you, right? That was very nice.

BTW, what is the name for that part and what is used for?

ichitaka05 · 09-02-2011, 01:34 PM

Quote:

Originally Posted by Want.FR-S

And she is the nice one who picked up the part for you, right? That was very nice.

BTW, what is the name for that part and what is used for?

Yeah, she have been nice. Maybe cuz, I'm really good friend w her fiance. Seriously without her picking up that fork, we couldn't install that part last night.

As for the part, I call it transmission fork, but technically called clutch release lever/fork. It's where slave cylinder push that part and it'll push the throw out bearing to the pressure plate.

It's #5 part on this pic

Allch Chcar · 09-02-2011, 09:21 PM

Quote:

Originally Posted by ichitaka05

Yeah, she have been nice. Maybe cuz, I'm really good friend w her fiance. Seriously without her picking up that fork, we couldn't install that part last night.

As for the part, I call it transmission fork, but technically called clutch release lever/fork. It's where slave cylinder push that part and it'll push the throw out bearing to the pressure plate.

It's #5 part on this pic

Very nice. Glad you got it fixed Ichi!

Marrk · 09-02-2011, 09:30 PM

I'm glad you got it fixed, too, but I agree with you that it seems like a strange part to have fail on you.

Allch Chcar · 09-02-2011, 11:18 PM

Quote:

Originally Posted by Marrk

I'm glad you got it fixed, too, but I agree with you that it seems like a strange part to have fail on you.

My guess is that Ichi-san is one bad dude. And the fork snapped from the strain O.O

Want.FR-S · 09-03-2011, 12:06 AM

was this part exposed underneath the car? It seems that it was rusted and then split by force...

ichitaka05 · 09-03-2011, 03:12 AM

Quote:

Originally Posted by Allch Chcar

My guess is that Ichi-san is one bad dude. And the fork snapped from the strain O.O

You know me, I have heavy left feet LOL

Quote:

Originally Posted by Want.FR-S

was this part exposed underneath the car? It seems that it was rusted and then split by force...

Nope, it comes out top of the tranny and get to about mid of the tranny

Update:

Everything is installed and fired out without problem... except, clutch kinda get stuck at the end (end is right word?). When I press on the clutch all the way in and lightly/slowly release it, it doesn't come up.

So I thought, it might be air in the slave/master cylinders, so bleed it for about an hr, so still gets stuck.

Any ideas/suggestions/advice??

OldSkoolToys · 09-03-2011, 03:18 AM

Yeah, that shit sucks ichi. But you gotta admit there's always that silver-lining to finding the true culprit to your problem...and that is, you finally know the true problem and can fix it.

Of course, in my AE86's case, my bizarre timing w/ throttle hesitation and bogging issue turned out to be a busted crank pulley and chipped crankshaft resulting in a rebuild/replace engine scenario......

Good news is I found a rebuilt 4A-GE extremely close by and the guy wants to get rid of it (and his '78 Corolla he was planning on putting it in, contemplating that purchase atm). Shouldn't be more than a few weeks before I get her back up and on the street.

Your clutch pedal is staying on the floor when you press it, even after bleeding? Maybe the fork is sticking now? I would have your friend manually push the clutch pedal back up and then press it again while you watch the slave cylinder and see whats going on. Maybe fidgeting with your slave like you did accidentally broke the cylinder? Looking at that diagram...the spring maybe?

Unfortunately I have very little experience on clutch work. I replaced the clutch in the 86 a few years back and that was it. The only issue I had was that my pedal wasn't engaging the clutch enough, even when fully pressed down. I 'fixed' that problem by tapping on a small 9mm socket at the tip of the slave cylinder to give it more push. =P

09-02-2011, 05:06 AM	#4
Giccin (╯°□°）╯︵ ┻━┻ Join Date: Dec 2010 Drives: Yaris HBK, Audi 09' TTS<Had> Location: Orange County~~~ Posts: 5,162 Thanks: 4,345 Thanked 1,899 Times in 966 Posts Mentioned: 87 Post(s) Tagged: 1 Thread(s)	That sounds terrible. I have a hard time doing tire rotations and oil changes. LOL WHERE ARE MY RHINO RAMPS!!?! Glad it worked out Ichisan __________________ I am the Ice Queen. Logic > Emotion ┬──┬◡ﾉ(° -°ﾉ) Yashio Factory Pink adds +10HP to anything. TOYOTA FT-86

09-02-2011, 02:40 AM	#1
ichitaka05 Site Moderator Join Date: Oct 2009 Drives: ichi 86 Project Location: Middle of No where Posts: 21,050 Thanks: 7,728 Thanked 19,278 Times in 8,388 Posts Mentioned: 697 Post(s) Tagged: 28 Thread(s)	Car nightmare Left is new one, right is old one. Yes, that old fork is broken in 2 pieces. K, it's gonna be hellova long post, so bare with me on this bitching. 2 weeks ago, I was noticing I have hard time shifting the gear. So checked under the hood and see what's wrong w friend. We thought clutch master cylinder went bad (cuz I saw some wet spots), so I called around all the auto parts store and if they have em... sadly no one in the valley had it so I had to special order it (only took 1 day to deliver). Saturday part came in, so install the clutch master cylinder and start bleeding it, I notice that fluid is leaking from clutch slave cylinder too. Tell myself "FML moment #1" and called around to see any shop have slave cylinder. Lucky enough Pep Boys which was 3x more than Auto Zone was asking for was the only one that had it (I didn't want to wait til Monday), so went there and got the slave cylinder. After buy damn expensive slave cylinder, start installing it. When we start to bleed it, we see fluids coming out between the rubber and the metal stick thing... "FML moment #2". Slave cylinder they gave me was defect. Try to call them back... but they've already closed for Saturday (WTF 8pm on weekend? WTF?!?) Sunday, called them and see if they have another slave cylinder, but they didn't have it at the store... correction, closest store was next state (Idaho!). They told me that it's gonna take 5~7 days to ship it here. Fuck that, I can't wait that long to get it, so got my money back. Damn expensive for nothing! Monday, on lunch break try to head to Auto Zone to special order in slave cylinder, but I got caught up on all the files and I didn't have time to go to Auto Zone before noon (if you special order before noon, it'll come next day 3pm). Tuesday, went to Auto Zone and special order the slave cylinder and they told me that it's be here Wednesday 3pm. Cool! Wednesday, call Auto Zone 4ish to see if the part I've order have came in. After 10 plus mins put it on hold they finally have it. Got the part and start installing the slave cylinder. After everything is gone, still not working properly... I was telling myself "WTF, why isn't working?" looking closely at the transmission fork (which slave cylinder pushes), it wasn't pretty and it moves around badly... so I've put flashlight inside to see what's up w it just to see 2 huge cracks on the fork! "FML moment #3". Start calling up all the shops again if they have it. None of em had it, so I had to call the dealers to see if they have that fork. Call 4 dealers and none of em had it. Call one small Subaru dealer and amazingly enough they had it... but sadly that dealer is over 30min drive and they told me that they gonna close that parts department at 6pm... and it was 5:45pm. Lucky enough my friend's fiance live 5mins away from that dealer, she was nice enough to go there and pick it up for me. Today, I've pulled off drive shaft, and everything that gets in the way of separate engine and tranny. After 7 hrs of sweat, scream, swearing, and all those things. Friend and I have pulled off the trans fork & that pic at the top is it. Tomorrow, I'll be installing everything back together again. Seriously, how in the fuck you break a trans fork? that thing is pretty hard. I don't slam on my clutch... Ah whatever, I'm just glad this thing is over with __________________

09-02-2011, 03:23 AM	#2
WingsofWar MODERATOR-SAMA Join Date: Oct 2009 Drives: Swagtron Scooter Location: Seattle Posts: 2,685 Thanks: 345 Thanked 1,562 Times in 524 Posts Mentioned: 81 Post(s) Tagged: 0 Thread(s)	oh god, i have the same engine and transmission on my legacy. I hope my fork doesnt go out on me. Iv been having some clutch engagement chattering problems, like when i get into gear and go, the car likes to lunge back and fourth like the clutch is grabbing then not grabing then grabbing again about 3 times before it gets smooth. I gotta bring the revs up higher than im comfortable with to get smoother engagement. __________________

09-02-2011, 09:30 PM	#10
Marrk Senior Member Join Date: Jul 2011 Drives: Honda Fit Location: Los Angeles Posts: 1,004 Thanks: 722 Thanked 125 Times in 90 Posts Mentioned: 2 Post(s) Tagged: 0 Thread(s)	I'm glad you got it fixed, too, but I agree with you that it seems like a strange part to have fail on you.

09-03-2011, 12:06 AM	#12
Want.FR-S Senior Member Join Date: Aug 2010 Drives: 4 Wheels Auto Location: Canada Posts: 1,191 Thanks: 251 Thanked 274 Times in 187 Posts Mentioned: 4 Post(s) Tagged: 0 Thread(s)	was this part exposed underneath the car? It seems that it was rusted and then split by force...

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