Rattle in Bellhousing after changing clutch

[scoots]

The car is a VN series1 5 speed.
When I got it it had a bad rattle which disapeared when I pushed the clutch in. On investigation, the clutch fork was bouncing around coming into contact with bellhousing.
I replaced clutch, pressure plate, throwout bearing and the two little rubber bumpers in the clutch fork (where the throw out bearing sits). (the pressure plate fingers were bent which I guess was causing the clutch fork to bounce around.
It's all back togethor but I now have a metalic rattle in the bellhousing. It sounds like a bolt or something is making contact as the clutch etc goes around. The clutch fork sits dead still. and again the noise disappears when you push the clutch in.
I pulled off the dust cover and the starter motor is definately releasing, and with the dust cover off, I can definately hear the noise from the clutch area.
Looking through the clutch fork opening in the bellhousing when it's running, the throwout bearing is sitting square and not wobbling around.
I used a clutch alignment tool when putting it back togethor and the box slid in sweet. Have I stuffed something up? Could it be input bearing? At least it's not an electrical problem
Any ideas?
Regards Scoots

[Boonz]

did you adjust the fulcrum ball to 102mm from the top of the bellhousing???? is the retaining clip still in the clutch fork?? mine had a similar noise and i adjusted the fulcrum ball to the correct specs and it went away

[scoots]

Yeah mate checked the pivot ball height. 102mm as per manual. The clip is attached.
(Actually the pivot ball height thing had me wondering a bit. The only way the height could vary would be for the pivot ball to wear down or the lock nut to loosen allowing it to move - or am I missing something here? I know how to measure it and adjust it, but I can't really see how the measurement would change at any given time once the lock nut is done up properly)
Thanks and regards
Scoots

[Boonz]

nah it can move if another person before you hadnt done it up properly.... does it make like a solid sounding knock or more of a ticking sound.... mine used to do it after 1500 rpm and go away as soon as there was a tiny bit of pressure applied to the clutch....

[scoots]

Describing sounds is a bitch, eh
The last time I heard a sound like this was when I changed starter motors on a VB and didn't put the dust/inspection plate back on properly. The flywheel was making contact with the inspection cover making a definate steel on steel type rattle. That's why the first thing I did on the the VN was pull the inspection cover off again. But made no difference in this case.
The noise dissapears when the clutch is about half way to the floor. When lying under car when it is running, you can grab the clutch fork and it makes no difference.
Thanks for trying to help. I know it's hard when you're not standing in my driveway next to the car. (if you were, you could help me throw empty stubbies at it )
Regards Scoots

[Boonz]

no probs man.... may sound stupid but... did you put the clutch plate around the right way??? dont laugh at me for askin its been done before without people noticing...

[scoots]

Yeah funny, but that's been burning in the back of my mind.
I know I checked it, (had flywheel side written one side) And I'm sure I assembled it the right way around, or did I? Nah surely not, well mabey, not a chance, ummmmm.....
I'm 99% sure I put it around the right way, but I guess I'm going to have to pull it to bits anyhow, no matter what the problem is.
Thanks and regards
scoots

[phatvn5speed]

i also have the same trouble with my vn i have just replaced the clutch with a brass button clutch from direct clutches in qld. now as soon as i get up around 2000 rpm there is a knocking noise and crunching sound i have replaced the two little rubbers in the clutch fork and it is still there, and around 2500rpm the gear stick vibrates like all F#$K. i just want to fix the problem for a couple of months until i can afford to do a 2jzgte 6 speed manual conversion. so if anyone can help me out thanks.

[samuels]

The car is a VN series1 5 speed.
When I got it it had a bad rattle which disapeared when I pushed the clutch in. On investigation, the clutch fork was bouncing around coming into contact with bellhousing.
I replaced clutch, pressure plate, throwout bearing and the two little rubber bumpers in the clutch fork (where the throw out bearing sits). (the pressure plate fingers were bent which I guess was causing the clutch fork to bounce around.
It's all back togethor but I now have a metalic rattle in the bellhousing. It sounds like a bolt or something is making contact as the clutch etc goes around. The clutch fork sits dead still. and again the noise disappears when you push the clutch in.
I pulled off the dust cover and the starter motor is definately releasing, and with the dust cover off, I can definately hear the noise from the clutch area.
Looking through the clutch fork opening in the bellhousing when it's running, the throwout bearing is sitting square and not wobbling around.
I used a clutch alignment tool when putting it back togethor and the box slid in sweet. Have I stuffed something up? Could it be input bearing? At least it's not an electrical problem
Any ideas?
Regards Scoots

did you lubricate the throw out race? as stated by peanuts....clutches have been known to be put in back to front.did you check spigot bush,could be buggered or non existent.? also how does the clutch pedal and free play feel with the foot,cable could be stretched,causing clutch to be almost always engaged

[scoots]

Gidday Samuels. I packed the inner recess of the bearing with bearing grease.
With the car running you can grab the clutch fork and move it back slightly so the throwout bearing is not making contact with the pressure plate fingers so I dont think it's a noisy bearing problem?
I checked the spigot bush and the end of the input shaft which goes into it but both seemed fine. I lubed it with a small smear of bearing grease, and when putting the box in the last 10mm was snug, so presume the input shaft to spigot was a nice fit?
The adjustment seems fine. When driving everything works sweet. No slippage and smooth gearchanges.
Mabey I stuffed up the clutch plate orientation. For the life of me I can't think of anything else that might be causing the problem???
Thanks
Scoots

[scoots]

Well I started the car today and the rattle wasn't so bad. As it warmed up the noise seemed to get worse. Heat related steers me towards bearing problem. I drained the dexron3 out and replaced it with 70/85 gear oil and, I don't know if it's my imagination or not, but the rattle seemed to be a little less harsh, which would confirm bearing problem.
I can only imagine it's an input bearing transferring the noise down the shaft to the bellhousing area. Pushing the clutch in would give the shaft more support making the rattle dissapear????? Who knows!
At this stage I'm just going to leave it and see how it goes. Hopefully it will last ok until I get around to doing a box rebuild.
Thanks for your help guys
Regards Scoots