peetrock

So.....

I just put in a new clutch (NAPA stock replacement) clutch plate, throwout bearing, pilot bearing, flywheel, master cylinder, slave cylinder, new hydraulic lines, bled the system, adjusted the master cylinder plunger and I have a wicked chatter in all gears. What do you think? Buy a new truck? Get an more powerful clutch cover, like a HD Marlin, and if so, do I need to replace the clutch disk as well?

Thanks!

peckinpah

I had the same problem right after I replaced my clutch, within maybe 300 miles after. I backed down the clutch pedal plunger rod (if that's what you call it) about 3/8th's of an inch and the noise stopped. Evidently my clutch pedal was set too high. now it sits slightly lower than my brake pedal.

I admit that I'm not sure exactly how the rod is supposed to be adjusted, but this is what worked for me, and I'm not messing with it any more as long as it stays quiet.

Mine was a cheap Kragen clutch, IIRC.

YMMV.

peetrock

Right. This happened within the first 5 miles of driving. It's already starting to engage right off the floor. I even stopped to adjust the plunger in a little more to see if it helped. It did not. I'll adjust it again to see if it works. If not, I may take the new NAPA kit back and pay the extra for a Marlin or Centerforce.

Thanks

justin_4runner

check to make sure the fork is sitting right, might not be all the way in place.

peetrock

Fork sitting right as in pushed all the way into the bell housing? I'm pretty sure it is. Would the slave push rod line up if it wasn't fork wasn't in all the way? I know that it is in the pocket on the fork.

peckinpah

To be honest, I can't remember if I raised the adjustment rod or lowered it. But I had a hell of a racket coming from the clutch, and I was sure I had a burned out throwout bearing or I installed something wrong and was gonna have to take the whole thing apart again. I damn near had a panic attack at the time.

If the clutch is engaging at the floor, I would raise the pedal up an inch or so.

All I remember is that setting the point where the clutch engaged fixed the problem of the noisy chatter. I played around with raising and lowering the adjustment rod until the noise stopped, and this was in 2008 and it has worked fine ever since.

Now it's just one of many scares I have had with my truck that turned out to be nothing.

justin_4runner

yeah it would still hit it, on the trans there is a bolt with a fat round head there and the fork clips on it with spring like clips holding it there, thinking if its not pushed in place right then it might be causing a little drag on the clutch pressure plate.

peetrock

Sweet. Thanks. I'll try this stuff when I get home this evening. First I'll check the fork placement then then readjust the plunger to get the pedal off the floor. Hope it works!

Greg_Canada

When you installed the clutch, did you bolt them all down a little bit at a time in a criss-cross pattern, or did you install 1 bolt tight, all the way around? If you didn't do a criss cross pattern tightening alittle at a time, you may have bent the clutch disc.

peetrock

I tightened a little bit at a time going to the opposite bolt and torqued it to the specs in the manual. I also just checked the fork. It appears to be in all the way and lined up with the plunger on the slave. Gonna try readjusting the plunger again.

corax

remember also not to do any full throttle launches for the first 500 miles so it'll break in properly - google "clutch break-in" if you have any questions on how to treat it. Also, you did clean any oil or cosmoline off the flywheel and pressure plate friction surfaces, right?

shafner30

Its goes away....

I just put a new clutch in my 1990 toyota pickup 2wd with 396 thousands miles on it no joke..

It takes about 3 to 5 thousands miles...

Hang in there..

peetrock

Absolutely! Clean as a whistle, both the flywheel and cover. Both when I opened it up and just before they got bolted on.

A while back I put a clutch in my old Civic. No problems with chatter, slip or anything right from the first mile I put on it. The problem with the truck is that it chatters from first through fourth with a little or a lot of gas. Seems strange. Maybe the cover is bent. I might take it off and check it if some more plunger adjustment doesn't work.

Thanks for all the tips.

peetrock

OK. Talked to a buddy of mine who does this all the time. He said it is an unbalanced flywheel. There is a symptom that I just noticed after taking it for another unsuccessful test drive. If I'm in neutral with the clutch out and rev the engine, the whole truck shakes for a moment. There's also a low hum at around 3000rpm that wasn't there before. I just noticed these tonight. I was probably paying attention to the chatter during previous test drives. Gonna get the old one resurfaced and take the New flywheel back. I should have done that in the first place.

Thanks for all the help. When I reinstall the flywheel I'll keep the suggestions you all gave in mind, just to make sure I don't foul it all up.

Peetrock

corax

also make sure there was no grit between the flywheel and crankshaft, that could cause a wobble

peetrock

Tear down tomorrow. I'm getting the old flywheel machined today. Hope it all works.

Magnusian

Doesn't seem like a tear-down will be necessary, see this post and the thread it comes from:
https://www.yotatech.com/51678074-post7.html
https://www.yotatech.com/forums/f115...clutch-230439/
It should work itself out.