Trying to figure out why my reman 6-speed is failing...

[DK77]

Already ordered a new fork/ball from Ninja

[TwIzTeD_3kGt]

That's looks to be a lot of play between that ball and fork, mine has no play. Judging by the absolute lack of grease where there should be grease, I would say the clip on the backside of the clutch fork has worn out. I think it's popped out and can't hold itself in maybe? Mine does not move up and down so easily when it's popped on the ball. That ball and fork recess should be packed with wheel bearing grease or equivalent. Check the manual and start greasing what it says to grease. Excellent video btw.

So would the fork not being shimmed properly potentially cause the TOB/gear rattle that annoys me so much?

You sure it's not the clutch rivets? I haven't had a TOB rattle ever, even though I assume its TOB everytime, it's always the clutch rivets. When exactly does it do it?

[DK77]

What I'm talking about is when you let off the clutch pedal my car rattles from the trans/clutch area. If I press the pedal far enough for the clutch to start disengaging the rattle goes away. I always assumed TOB until I replaced it with a new OEM one and had the same issue. I've now had this issue with 3 different clutch set ups; 3 different transmissions; 3 different TOBs; and at least 2 clutch forks. It drives me nuts. I've heard that it's a rattle internally in the transmission having to do with bearing clearances or backlash or something like that. I don't know how to fix it but it's kind of embarrassing lol.

[TwIzTeD_3kGt]

What I'm talking about is when you let off the clutch pedal my car rattles from the trans/clutch area. If I press the pedal far enough for the clutch to start disengaging the rattle goes away. I always assumed TOB until I replaced it with a new OEM one and had the same issue. I've now had this issue with 3 different clutch set ups; 3 different transmissions; 3 different TOBs; and at least 2 clutch forks. It drives me nuts. I've heard that it's a rattle internally in the transmission having to do with bearing clearances or backlash or something like that. I don't know how to fix it but it's kind of embarrassing lol.

That's the exact scenario I had with the stock clutch, XTD 3, and Spec 4+ (twice). All were clutch rivets loose. I would sit at stoplights with the clutch pedal pushed in so it wouldn't embarrass me. I could also make it not rattle if I let the clutch pedal out VERY slowly. If something inside the trans was rattling that often and loud enough for you to hear in the cabin, you would have all kinds of metal in your trans oil. Not saying it couldn't be something else, but that's all it ever has been for me. Usually make it a few thousand miles on a new clutch before it starts happening. I think it's the launches that causes it to loosen up.

[DK77]

Interesting... This has happened with a SPEC stage 2 disc, an OEM disc, and right now an ACT 6 puck unsprung. This clutch did it right away with no abuse on it at all. I've only launched the car once but it was rattling even before that. So is that something I could have fixed when I put the new clutch in? Like have a machine shop put in beefier rivets?

[TwIzTeD_3kGt]

Interesting... This has happened with a SPEC stage 2 disc, an OEM disc, and right now an ACT 6 puck unsprung. This clutch did it right away with no abuse on it at all. I've only launched the car once but it was rattling even before that. So is that something I could have fixed when I put the new clutch in? Like have a machine shop put in beefier rivets?

If that's the issue, then yes. Not sure a machine shop will do it, but I have local clutch/brake rebuilding/manufacturing company that will let you ship in your clutch. They're making my custom clutch and fixing my Spec 4+ again right now. I haven't had it happen immediately after a new clutch install with any of the clutches, just after a bunch of launches and a few thousand miles, so your issue could be different entirely. Sounds like you've eliminated everything to do with the transmission with all the parts you've been through.

[NOMIEZVR4]

problem found. see attachment

[anyonebutme]

that'll do it, lol

[TwIzTeD_3kGt]

It dun broke!

[DK77]

After inspecting the new fork and ball that arrived in the mail, I'm thinking that my rattle issue is due to the retainer clip being bent/worn. It was not nearly as hard to put the old fork on the ball as it is with the new one.