Bellhousing Noises, Brake Booster Not Working

[DearmanKE]

Yo

 

just got my new 4k, exedy hd clutch and 5 spd, running in the ke70

 

theres alot of noise comeing form the clutch area, when its adjusted so that the clutch only has be lifted a little bit off the floor the clutch engages it has a loud whirring sound

 

and if i adjust it out so that it has more of a normal position it whirs and whines and screaches, also the more i poush the clutch down thats when the noises seam to get worse.

 

when i did the clutch/gearbox i replaced the release bearing with the new one which came with my clutch.

 

 

my other problem is the brakes are realy teerible, it seams like the booster is not working, i connected the inlet manifold to the one way plastic valve with a different hose that is slightly longer and slightly more curvy but i don't think that shoudl have an effect,

 

the car had been sitting not moved for approximatly 3 months, possibly even more 3-5.

any way i can test my booster?

 

cheers

 

-Alex

[styler]

heres a possible scenario - your clutch friction disc is on backwards

and you are using you pcv valve hose not the the vacuum booster hose

that you should be using.

[DearmanKE]

hmmm prety sure clutch is on the right way because i remember being like which way does it go then finding written on it TM side(transmission).

 

and as for the booster, its the correct hose and the valve is the right way round, but id ont get it how it worked bfor n now it doesnt,

 

anyway, guess I'm gunna have to pull the gearbox out, ive got a feeling the release bearing might not be clipped on properly,

 

also whats the proper way to grease the bearing as i may not have done a good enough job, i sorta just rubbed my greasy hands all over it lol.

[irokin]

ive got a feeling the release bearing might not be clipped on properly

 

That'd be my guess. Whatever it is it's a gearbox off job.

[styler]

hmmm prety sure clutch is on the right way because i remember being like which way does it go then finding written on it TM side(transmission).

 

and as for the booster, its the correct hose and the valve is the right way round, but id ont get it how it worked bfor n now it doesnt,

 

anyway, guess I'm gunna have to pull the gearbox out, ive got a feeling the release bearing might not be clipped on properly,

 

also whats the proper way to grease the bearing as i may not have done a good enough job, i sorta just rubbed my greasy hands all over it lol.

 

*edited - was arse about tit on friction disc install*

 

are you sure TM isnt for trademark? lol just kidding but seriously the sprung centre section

(the bit with the springs in it) should be proud of the friction disc (look at the friction disc side on

and see the whole section that is raised on one side of the disc only) and that raised section of the

disc resides in the clutch pressure plate side (transmission side) not the flywheel side (engine side).

i don't know if thats your problem but i had the friction disc installed on backwards the first time i

ever worked on a car and was trying to change my clutch assembly, i had similar problem diagnosis with

pedal movement and associated horrible noises as well as being covered in gearbox oil, when i pulled

the tailshaft out to begin removing the gearbox :'( the things you learn... i had to throw my clothes away

as the stench never leaves anything it touches.

 

check bearing, make sure clips are working (should put in new ones) and always use a new bearing

which you have done. you grease the sliding section of the throwout bearing mechanism if i remember

correctly and the wet the input shaft (wipe on / wipe off) and I'm not sure about greasing the face that

touches the pressure plate as some people do it but i don't think you should have to as the bearing face

spins on grease anyway and external grease at 6000 rpm probably will go onto the friction disc with bad results.

 

did you get you flywheel step machined again? you should always do that for a new clutch :P

 

else could be your old pilot bearing is worn (the gearbox input shaft bearing which is hosted in the

end of the crankshaft)

Edited December 7, 2008 by styler

[DearmanKE]

hmmm interesting

 

I'm pretty sure the friction plates side that was prouder i put towards the gearbox because that was the one that said TM side :'(

 

anyway il be pulling the box off sometime in the next few days, if i have the energy will most probly start 2nite, unless i go out and get maggot in which case i probs wont start till monday lol

[DearmanKE]

well i pulled the gearbox out today

 

and you guys are guna laugh at me, because i actually suck lol

 

 

k40's and k50's have a small rubber boot that goes over the clutch fork on the outside of the bellhousing

 

i had installed this boot on the inside because i was like it wont matter which way it goes(coz at the time i didint realise they went on outside and i assumed it was inside because of the spring on the outside sort of being in the way.)

so yeah i installed it inside

 

 

so the rubber boot was rubbing against the pressure plate slightly creating the whirring, and then when the clutch was depressed it was pushed further against the plate createing the screeching noise!

 

lame, anyway when changing the clutch fork with another bfor putting the box back in(coz the other fork had a better end clip on it)

i accidently strecth my release bearing clips, so yay more fun for me lol

 

 

oh and 2moro or wednesday should be getin another brake booster