Got a head scratcher for ya - rattle on startup, finally dropped the tranny today and found this damage on the transmission quill, exactly opposite of the fork entry. I've got another 5 speed to throw in luckily, any ideas as to root cause? Stock flywheel, act organic clutch with heavier pressure plate. Pilot bearing seems okay.

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TOB condition?

Maybe PM mr_hyde and ask if he ever figured out his issue?

 

Can't *really* tell the condition of a bearing unloaded - but it spins freely by hand, not gritty. It's just.. weird. The opposite side of the shaft doesn't show any damage, so the TOB was engaging the fingers straight / not cocked. My best guess is that it wasn't sliding in the fork as it went through it's arc, despite the contact points having grease. I measured about 5 thou of runout on the powdercoated pressure plate - which for a non machined surface I think is fine.

 

That's an odd wear pattern. I've no idea what the problem is.