horrible noise when I disengage clutch

[1999 996C4]

Hello all.

I did something wrong and maybe you know what.

I just did a bunch of things with the trans out including replacing the clutch and updating the release lever and associated hardware. When I fired it up it made a nasty grinding sound which went away when I released the clutch. It returns whenever I push the pedal past about 1/2 way. The spring feedback on the pedal is different from before but not unnatural. My suspicion is that the release lever is not sitting on the ball properly (or not at all), but the other end seemed to be in the right place to accept the slave cyl pushrod so I thought all was well. I did read something about using tape to hold something in position but didn't do this and the Bentley manual doesn't mention it.

Any suggestions? It is on axle stands on a 4 post lift in case that makes it possible to do something to narrow it down.

Thanks

[1999 996C4]

Hello again

I have a new theory -The release lever seemed to only fit 1 way so I didn't dwell on it when assembling, but looking at the old one it appears that it slides on the throwout bearing enough that it could go in either way - and if memory serves, I put it in backwards. Any comments appreciated - and and can anyone shed some light on the tape issue?

[1999 996C4]

Okay, although nobody seems to be interested in this, I'll put it to bed: It was the new style release lever being backwards and after another 4 or 5 hrs work all is well, FYI - the side with the rubber washer goes on the fulcrum side not the slave side.

Experience is what you get just after you needed it.

[logray]

Good work. I was going to say you need to drop the tranny again. Just about 110% of the time when you hear noises in that area, except for the rare slave cylinder case.

[dphatch]

Okay, although nobody seems to be interested in this, I'll put it to bed: It was the new style release lever being backwards and after another 4 or 5 hrs work all is well, FYI - the side with the rubber washer goes on the fulcrum side not the slave side. Experience is what you get just after you needed it.

Not lack of interest but lack of hands experience with the problem I suspect. As logray suggested, and regardless of the problem, it would require removal of the tranny to investigate. As you had already come to that conclusion, wasn't much else anyone could offer unless they had experienced the same issue. None the less, good to know about the change in release lever for those who maybe tackling the same project in the near future.

[skatteba]

I read your post with great enthusiasm as I am about to embark on a clutch job myself. I have also purchased the upgraded release lever and know with my luck that I would have put it in backwards. So, if you ever find yourself in Norway, I'll buy you a beer, as you saved me many hours of extra work :wrench: