Wow! A replacement piece for the nylon thread! I was about to give up on my DT3 project because of the clutch actuator. I don't have the skills or the tools to do the cover mods that I have seen. I hope this will work.
I too suffer from the stiff clutch and throw of the actuator..I will report when I get it installed.

Has anyone actually installed a new brass piece on the actuator shaft? I'm curious as to how it's actually fastened to the shaft. I'm assuming a press fit over the spline shaft?

I ordered through KDI but the eBay sight said that they come with instructions. I am assuming the KDI unit should come with the same instructions.  I have found that the orientation of the threads is important to get the proper rotation/push of the rod.  I have several actuators; all with split nylon that seem to have different amounts of rotation. I think if they split, they loosen up on the shaft and slip a little thus changing the amount of rotation. Dang I really want to get this problem fixed!

Thanks, mine is still good but I know it's only a matter of time so I think I'm going to order one. I don't want to hijack the thread but this is all good info.

I spoke to Dave Kolbo about the installation and he confirmed that the actuator comes with instructions on how to install and orientate properly. I will be ordering one soon.