Wow, this has been covered many times before; however, lets review:

1) I broke a '93 clutch fork with a stock clutch at about 120,000 mi.(probably related to # of flexure cycles);

2) The problem isn't the material, it's with the stupid roll pin hole that's drilled into the tension side of the casting. This is where the cracks begin and emanate from. The material is otherwise a good quality cast steel.

3) I've TIG welded up a broken fork, reinforcing the weak section with good results as it didn't break in 10 years of daily use. I've also been using a fork similarly reinforced (by removing the offending hole) behind an Act Xtreme clutch for the last 3 years in daily service (>40,000 miles) with no problems whatsoever.

 

Crap, now im scared to drive my car lol

I guess if its gonna happen, its gonna happen.

Maybe i should make a list of things to do so when the fork breaks, ill do those things together.

Well not me, prob JPR or another good shop.

 

Well, I sent the FD off to the repair shop this AM to have a fork-ectomy. It looks like it will handle real well, strapped down on the roll-back truck. New '96 J-spec clutch fork was $87 plus $8 shipping from Malloy Mazda. Arrived one day after it was ordered by phone.

Note to self: Buy four-post garage cable lift for Xmas present this year so under-car repairs can be done without using a creeper.

"Any repair is a good repair, if it results in buying a new tool"