Hello world, first time since I have exhausted finding existing info on my issue. I'm replacing the clutch on my 2006 R53 MCS since I was having excessive pedal travel that wasn't solved by bleeding the slave, multiple times. With 180k miles, it was time anyway and a good excuse to do all the other things like supercharger, water pump, ball joints, anti-sway bar bushings, etc. What I discovered was the throwout bearing was wrecked and has worn into the clutch release fork (see image). The flywheel, clutch, etc looked fine, so seemed like just putting the new Valeo kit on and replacing the fork and I'd be on my way. However, after removing the bolt from that goes through the shaft, the fork does not want to move, at all. Being careful not to damage the bellhousing, I am not putting full force to try to make it move, so I am hesitant to go much further.

I have not found any threads or info on on the web about this being an issue. Can anyone help me understand if this should slide right off, is it pressed on and I will have to remove the entire thing, can I cut it off with a hack saw or die grinder, put some heat to it to get it to move? Other ideas?

I am the original owner with this being the first time the clutch has been done and everything in this job has gone really well, so getting hung up on one thing kinda sucks. Please advise. Thanks everyone.

 

Hey, what eventually happened? Planning on digging in soon.

 

I had the same issue when I did my clutch. Spray some penetrating oil in the bores that the shaft goes through and carefully tap. It will come loose and then you can slide it out. I replaced the bushings while I was at it.