Getting the pin out of the clutch fork can be tedious. It depends on
where the fracture actually occurs. It will fracture near the pin and
crossshaft mating surface, on either end. The first thing to do, much
as I hate to say, is pull the gearbox out of the car. Once out, remove
the throwout bearing and sleeve. This will give you enough room to pivot
the fork into position.
Now the first thing to do is unscrew the head of the pin and see how much
is left. Chances are, as you say, there won't be enough clearence to get
a drill in from the direction the head of the pin came out. You might be
able to pull the cross shaft out enough to get one end free of the bellhousing
but don't count on it. If so, drill into the old pin and use an extractor
of some sort.
If not, what can be done is the drilling of a small hole into the crotch of
the fork and driving the remnants of the pin out with a punch. The critical
part of this operation is to first, use as small a drill as you can, maybe
3/16 is what I've done in the past. Secondly, don't weaken the fork by
drilling through the web. This should be more obvious once the thing is
staring you in the face. Drill in the corner by the side of this reinforcing
web, aiming at somewhat of an angle towards the end of the broken pin. Once
the drill gets through the fork into the pin, use a small pin punch to drive
out the clutch pin remnants. Make the hammer blows as square to the punch as
you can, you don't want to break the tip of the punch off by bending it.
Or, just obtain a new crossshaft and clutch fork, then cut out the old one
with a die grinder and some cutting wheels.
The optimal solution, of course, is to replace this pin every time you are
mucking about with the clutch to avoid this in the first place.
mjb.
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