New Clutch Noise

[NJBronk]

I finally got everything back together and overcame a few small hiccups trying to get the Bronco back on the road. Finally time for a test drive, and I hear this sound when I depress the clutch:

https://photos.app.goo.gl/7Ai1ccQBRxjoNy5z6

The sounds comes when I push the pedal and then goes away when I release.

Could the (new) throwout bearing have come off the fork while installing? Not sure how that would be possible. Doesn't sound like the bearing itself is bad, but it's a really weird sound. Anything I could/should check before taking the whole transmission out again?

 

[73azbronco]

sounds like bearing is spinning and hitting fork, got a borescope? Cheap at HF. Or mechanic mirror and flashlight

 

[NJBronk]

sounds like bearing is spinning and hitting fork, got a borescope? Cheap at HF. Or mechanic mirror and flashlight

So meaning it's not clipped onto the fork properly, or the bearing is broken / crooked? I can try to get a look in there, but would the resolution involve removing the transmission anyway?

 

[NJBronk]

I was able to get a picture of the bearing side. Looks like maybe a gap between the bearing and fork, so I’m thinking the clips came off, but hard to tell.

Good excuse for a new tool (boroscope); I’ll try to see the other side where the clips would be over the fork. Then try to wriggle the fork back onto the bearing before tearing everything back apart.

 

[73azbronco]

is there wear on the fork?

 

[NJBronk]

is there wear on the fork?

It’s a brand new fork. Old one almost had a hole worn straight through it from the clutch rod…

 

[DirtDonk]

It’s an often forgotten wear item.
Or I should say a service item, because it needs to be greased as part of the regular grease regimen.

That’s a horrible sound! Don’t think I’ve ever heard a clutch make that noise.
Only thing I can think of that is clutch related, would be a disintegrating disc. Or a bolt head hitting something.

It sure sounds like a non-clutch noise to me though. Can you use a stethoscope to determine if it’s engine or transmission related instead?
Reason I ask, is because when you depress the clutch multiple things happen.
Including disengaging the disc and transmission, but more importantly, pushing forward on the crankshaft.
Hmm, if it was some kind of an external bolt, such as for the starter, I would think it would get worse when you were depress the clutch pedal, rather than better.

Can you duplicate it just by spinning the engine over by hand? Obviously won’t be as severe, but maybe you can hear a click when it gets to a certain point.

 

[JB Fab]

I was able to get a picture of the bearing side. Looks like maybe a gap between the bearing and fork, so I’m thinking the clips came off, but hard to tell.

Good excuse for a new tool (boroscope); I’ll try to see the other side where the clips would be over the fork. Then try to wriggle the fork back onto the bearing before tearing everything back apart.

View attachment 962883

Off topic, but what borescpe?

 

[NJBronk]

Borescope for the win! (https://a.co/d/09uhmiB4), and thanks to Amazon for overnight shipping.

I must have had the fork pulled out from the bellhousing too much. I was able to push it back onto the clips and noise is gone! So glad I didn’t need to remove the transmission!

Here’s the clip off the fork:

Then repositioned:

First drive of the year coming up!

 

[73azbronco]

awesome, now you need more tools! Ha.

 

[NJBronk]

awesome, now you need more tools! Ha.

Don’t tell my wife that. I’m waiting for Father’s Day sales to get a new 52” toolbox to help with overflow.