Replace or resurface your flywheel.
Many people also upgrade the shift fork, but it's not nessacery.

if you fork and ball seem okay regrease them.. and make sure they are nicely functional.. and like 99gst said.. either resurface or my thoughts(buy a new one) specially if your putting in a new clutch. a new flywheel will work better..

I say change the fork and ball even if they look ok. Make sure you bleed it properly and adjust the mc before you post a "engagement problem" thread.

How difficult would it be to replace the clutch in a 91 gsx for someone who is going to do it at home rather than take it to a shop?

mac 108 said:

How difficult would it be to replace the clutch in a 91 gsx for someone who is going to do it at home rather than take it to a shop?

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ill let you decide. your going to have to take the drive shaft loose to pull it out of the gear box and take out the gear box and the tranny (neither are that heavy) but puting it all back in will be a b****. it was kinda hard with a car lift and tranny jack so i couldnt imagine doing it on the garage floor. but while your down there dont forget check your gear oil in the gearbox and rear end.

when the tranny is out take a air hose blow out all of the crap like shreaded clutch ( if any, i had to cause the person who owned mine before me let his kid learn on it.) then take brake cleaner and clean it all up nice then re-grease. um and refinishing a flywheel is a must but i would recommend a prof. do it unless you wana risk having to take it all apart again to fix it.

Yes, while your flywheel is out, replace the rear main oil seal.

vfaq.com answers all of this!! well mostly... but you really should change the fork and pivot ball with a new clutch, I would also recommend getting a new slave cylinder with extended rod. You might as well do all of this at one time, while the trannies off. Throw in a SS clutch line also.

vfaq:
1g swap http://www.vfaq.com/mods/clutch-1G.html
2g swap http://www.vfaq.com/mods/clutch-2G.html

oldman said:

I say change the fork and ball even if they look ok. Make sure you bleed it properly and adjust the mc before you post a "engagement problem" thread.

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this is seriously the best advice in this post, especially if you're upgrading your clutch. I think I had my transmission out 4 times last year before I figured it out. The Fork looked OK, but it wasn't when I compared the old one to a new one. It should be standard procedue when doing a clutch from now on.

sherms_gsx_tank said:

ill let you decide. your going to have to take the drive shaft loose to pull it out of the gear box and take out the gear box and the tranny (neither are that heavy) but puting it all back in will be a b****. it was kinda hard with a car lift and tranny jack so i couldnt imagine doing it on the garage floor.

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I've done it twice in my garage on my 96 Eclipse, and yeah, it's a b****. You've got to raise the car as high as possible (if you don't have a lift), support the engine and lower the tranny. If you don't have the right tools for it, it can take forever. Also, several hard-to-reach bolts can cost time and bloody knuckles if you don't have all the right wrenches, extensions, etc. My advice is: make sure you have all the best tools for the job and someone available to help you with the heavy stuff (especially when you put the tranny back into place.) If you don't have all this available, it'll be worth the money to save the headache.

not really part of a clutch job...but while it is out you can easily get to the fuel filter and heater hoses. might change them now if it has been a while.

jim

FORMONTOYA said:

not really part of a clutch job...but while it is out you can easily get to the fuel filter and heater hoses. might change them now if it has been a while.

jim

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agree

i would definately replace the rear main seal, because if you leave that old one in it could start leaking and ruin your brand new clutch then you will have to do it all over again. and as almost everyone else said i would resurface your flywheel. and as far as the forks go that would also be a good idea, i recently put a clutch in my friends 240sx and about 10 minutes of driving with the new clutch the fork snapped. so there are my suggestions for you good luck.

JLeach50 said:

I've done it twice in my garage on my 96 Eclipse, and yeah, it's a b****. You've got to raise the car as high as possible (if you don't have a lift), support the engine and lower the tranny. If you don't have the right tools for it, it can take forever. Also, several hard-to-reach bolts can cost time and bloody knuckles if you don't have all the right wrenches, extensions, etc. My advice is: make sure you have all the best tools for the job and someone available to help you with the heavy stuff (especially when you put the tranny back into place.) If you don't have all this available, it'll be worth the money to save the headache.

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i highly respect you for doing it on the garage floor. but just a little mechanical tip to make everyones life easier. it seems obvious but you would be surprised at how many people dont do it. get the hard to reach bolts out first so your not trying to support the part your taking out while trying to remove the bolt

sherms_gsx_tank said:

i highly respect you for doing it on the garage floor. but just a little mechanical tip to make everyones life easier. it seems obvious but you would be surprised at how many people dont do it. get the hard to reach bolts out first so your not trying to support the part your taking out while trying to remove the bolt

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Very good point. For clarity, I wasn't saying that I had been trying to do it the hard way; just trying to keep the post short enough. But that is a good point. Use a manual and follow the steps in it; so much easier that way.

Thanks for the help.

Is there anywhere else to get an upgraded clutch fork? The only place i know of is Taboo, and i don't feel like waitin 3 years to get it.

Another piece of advise for tranny removal/installation...disconnect the battery! My friends gvr4 caught on fire when he was puttin his tranny back in, the starter somehow shorted, didnt' do too much damage, just some melted throttle cables, but still scary as hell!

Oh, and shouldnt' the axle seals be replaced also, i think?

dont forget throw out bearing

ericbev said:

dont forget throw out bearing

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Yeah, a lot of good clutch kits should come with one included. Make sure you get it if they advertise one. Otherwise, it's a $50 part at a dealership.

Mitsu90GSX said:

Is there anywhere else to get an upgraded clutch fork? The only place i know of is Taboo, and i don't feel like waitin 3 years to get it.

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You don't need an upgraded one, just a stock replacement will be fine. http://www.diamondstarmotorsport.com/drivelineparts.shtml only $62 for fork and pivot ball, it's the best price I could find online, and get the retaining clip too for only $5.