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Looks like I found my problem and yes, it was ridiculously simple. It was the alignment dowels, or lack thereof. I didn't notice that at least one was missing, maybe both. I've never had dowels come out of a block before so didn't think to keep track.
I'm installing a new clutch, flywheel, and another 6spd trans next week. I'm confident everything will be just fine, but will report back to confirm.
The missing dowel(s) would explain the apparent misalignment, which caused the knock and the flywheel dust shield to not line up. It all makes sense.
After a year and a half of pulling my hair out and breaking a 6spd and clutch... this was the culprit:
Hey, guys. I'm having a problem that NOBODY can figure out. I'm grasping at straws to see if any of you engine and/or trans builders have seen my issue before and could possibly give some direction. I don't expect free advice, but am hoping. I'm kinda desperate at this point, as I'm looking at killing my second transmission.
I'll try to keep this short as possible:
I put my engine back together and, for some reason, my transmission was making this noise. It's an OEM crank, rods, and pistons with new King and ACL bearings (I used one for the main, one for the rods.. can't remember which and ACL thrust.):
1. The video shows it as it's loudest. It wasn't quite as loud in the beginning, but got worse until the trans finally broke.
2. When I let the clutch out normally, it made the noise you hear in the vid 90% of the time. If I let the clutch out slowly, It wouldn't make the noise at all.
3. I put a 5spd on the car and now it's making the same noise, just a lot quieter.
4. One of the forks are what failed on my last trans.
I pulled the old 6spd transmission apart and found a broken fork. I've attached pictures, in case you are curious. Clutch is an ACT with HD PP, Monoloc and fixed 6 puck. Could the knocking caused damage to the fork, resulting in it's breakage?
Could it be something wrong with the way the engine was put together? This is the same flywheel I used before but it made no noise before the OEM parts were put back in. The crank is from another engine, as are the pistons and rods.
Crank Walk? Warped flywheel or damaged clutch (though nothing has been dropped, etc).
Thanks in advance for reading. I really am at a loss here. Hopefully someone can help. Thanks again.
Thank you and: Crap. the ONE thing i didn't do when I had the trans off is check them.
The last time it started making this noise, however, I pulled everything off to check the flywheel bolts because i thought i forgot to torque them. Turns out i hadn't, so i doubled the work for nothing LOL.
Not to say they couldn't have backed out this time..
bottom line is, I think I'm gonna have to pull the trans I just installed LOL. And the new fluids. And the new washers and seals
aaaaaaaaaaaarrrrrrrrrrrgghhhhhhhh...
And the new fluids. And the new washers and seals
aaaaaaaaaaaarrrrrrrrrrrgghhhhhhhh...
That's the one thing that bugs me about this car. That the transfer case and transmission share fluids and you have to drain them everytime you even think about working on either piece. I reuse the drain and fill washers though.
So I've been thinking, probably not the flywheel bolts seeing how this is an intermittent problem. It only does it when I left the clutch pedal up normally but will not do it if i release the pedal slowly.
I tried to take apart the six speed to see what was wrong with it, but cannot get it apart. The clip at the end has a tab snapped off so it's hard to get the spreaders on it. I read something about a nut or bolt I have to remove that is under a freeze plug somewhere but I'm not seeing that.
flywheel or clutch is bent/warped/damaged which caused vibration to the input shaft and beat the crap out of the fork.
Swapping them out soon, so we'll see.
Jul 9, 2016, 12:57 PM
