clutch replacement problems
 

Hi all,
Getting ready to crawl under the truck for the second time. I recently replaced the clutch in my 96 t100 5 speed manual, 3rzfe truck. Other than not bolting the boot back on everything seemed to be working fine. I could hear a little noise from the clutch plate reconnecting with the fly wheel, when it goes into gear, but its impossible to hear when the boot is on properly.

I had the fly wheel resurfaced, got a aisen clutch kit, everything bolted up rather easily even the tranny slid on like a champ. There shouldnt be any air in the line, I never opened the fluid line, nor took off the cap of the master cylinder.
Before I replaced the clutch, the pedal was not coming up off the floor and you had to lift it with your toe. Also if you left it in first gear, The pedal would stick, and pull towards the floor, and it would slowly start to drive the truck forward. This happened twice with the new clutch in it.

Anyways, I went out to go to the store and it sounded all gravely, and rattly. At first I thought it was the water pump, but its definitly coming from the firewall. It shifts into gear alright, and seems to get a little quiter when its in a gear rather than nuetral.

I realize my post count is low, as I usually read and search a lot before asking any questions. Any pointers will definitly be appreciated. Thanks in advance.

Are you sure it's not the clutch pedal bracket? The original ones had a tendency to crack...they would be steel/rust colored. The new replacement ones will be black.

Yer clutch master/slave units could be bad. A rebuild or replacement would be in order. How many miles do you have on the truck?

BTW...did you check to see if the clutch pedal return spring is still functioning?
31301A SPRING(FOR CLUTCH PEDAL)
90905‑08003 1 $8.30
http://i677.photobucket.com/albums/v...t-11120927.jpg

Replaced the pedal bracket a while ago. The truck has about 220k, on it, I actually redid the clutch probably about 120 or 130. It sounds like the spline or something in the bell housing is making a lot of racket(the gravely noises). I have the driveline dropped, And am in the process of removing starter, and bottom bolts.
The slave cylinder isnt leaking, nor is the master at the firewall.

My dad said it sounds like the throwout bearing. I didnt think it was directional, and it was a brand new one in the aisin kit. He said he has had bad new bearings before.

When I torqed down the flywheel, I used a lesser quality wrench. I just discovered that every one of the 12 bolts were loose about a 1/4 turn back from hand tight on the fly wheel. That would explain the noise it was it rocking back and forth on the bolts, Everything looks like it is still in good shape, like when I pulled it out of the box. So I am keeping my fingers crossed....

Thank you bamzippow for the help.

I swear I never saw a +90 degrees on the torq setting. No wonder they were loose. You live and learn, hopefully it doesnt cost lots of money when you learn the hardway..

Thanks fer the follow up! Glad you got it all sorted out. :D