I found that my clutch actuator rack was broke when I took the clutch cover off. One tooth (3rd) was broke completely off. It appears the clutch release shaft (gears) are in good condition. We couldn't see any wear. The tooth that broke off the actuator rack was lodged between two of the gears on the release shaft. I had another set of eyes review the release shaft gears to validate that they look okay. We don't have an electron microscope, just two sets of eyes. Anyone know how/why the actuator rack would lose a tooth?

The actuator rack part number I have is 420259203. I have an 04 X. My service manual doesn't list the part numbers, so I'm curious if this is the correct part number. If anyone can validate, I'd appreciate that. I'm assuming I need to order the actuator rack from a local dealer. Of course, they can get me the part number too.

I'm also going to replace the friction and steel plates. We found that my fibers measured @ 1.097in, the manual states the minimum of 1.0827in. Does anyone know the thickness of the new stock friction plates? Also, the steel plates measured @ .468in, the max wear in the manual is .453in. My friend and I are curious what the new stock measurements are. Looks like the Barnett 9 disc is the recommended choice from HPR. Any other options would be appreciated.

 

have u had the stiffer clutch springs for long?? .. they would put extra stress on the actuator rack, possibally causing it to break...

 

Oz,
I had the EXACT same problem as you. 3rd or 4th tooth (can't remember) sheered off completley. The rest of the teeth on the actuator looked like new. I found the missing tooth wedged in the release shaft. This occured shortly after installing 60% springs. Sorry I don't have the actuator part number off hand. Do a search and it has probably been posted before. Make sure you put a fair amount of grease on the actuator when re-installing. The new actuator has been holding up so far.

 

DSengineer: I ordered the actuator rack for $34 from my local dealer. The shop manual states "super lube grease" to be applied to the gear. Any idea where I can get some "super lube"? They may have that at our local 4Playz :-)

 

Hmmm. Whats so super about it? That sounds like one of Bombs marketing terms to sucker you into buying a tube of grease that only they sell at a 300% markup.

Just use a brand name grease from an automotive store. I use Mobile 1 Syn in my grease gun at home.

 

I'm down with that 300% markup. I have full syn in my grease gun too. Thanks.