That's odd that the rattling is only in gear (presume clutch pedal released and rear wheels spinning -- and in 6th gear based on prior post).

Reason is that regardless of being in or out of gear, the transmission input shaft is spinning, as are the pressure plate, flywheel, and the inside half of the release bearing, with the outer half of the release bearing being kept from spinning by the clutch fork fingers around the flats of the release bearing.

The only difference is the drag on the engine/dual mass flywheel that the wheels, rear-end, drive-shaft and tranny apply.

Might you be hearing the classic clanking of the ZF transmission and nothing to do with the fork and release bearring?

Does it also do it in 1st and 4th gear (the tranny's straight-thru shaft)?

Might it be due to the car being on jack stands and the wheels dangling, which can increase the wheel shaft u-joint angle and make slightly worn 'u' joints more pronounced and cause more pulsation drag in the tranny?

Or worse, might the new GM dual-mass flywheel be defective and not dampening the engine pulsations and tranny's large side shaft rattle?

Good luck on the clutch slave/MC change tomorrow.

 

Not odd. The trans makes noise when it's in gear. As you said, the clutch here is not a factor. Having it on jackstands worsens it. The suspension can't dampen out the trans noises nor can the road take slack out of the drivetrain.

I am now doubting myself on how much fork movement is acceptable with the slave removed. If you have to compress the slave cylinder when installing it, I'm inclined to say it's fine.

Start a new thread with that specific question in the title.

 

I got the new cylinders. going out now to Install them. I'll let you know what comes of it.

 

Well, the replacement master cylinder was actually broken, and wouldn't pump up pressure. Oh well, I swapped the old one back in with the new slave.

Ladies and gentlemen, I have no successfully changed the clutch in a ZF6 transmission!



There's a little slippage, and a little bit of fumage, but I assume that's normal. It actually almost went away at the end of the test drive.

And there's the issue of the small exhaust leak at the manifold...

But she runs, and having grip is a wonderful thing! Clutch actuation is perfect, and she slides into every gear without so much as a whisper of complaint.

I'm exstatic that I was able to do it!

 

Congrats...

Yea, it's a great feeling completing something like that ... awesome..

wow, broken MC, ouch -- presume you'll R&R it once another 'good' new one acquired (since its probably on its way out like its lower slave).

Don't remember having any slippage on ours, but did brakes at same time, so might have been too gentle and without realizing it broke it in while breaking in the brakes.

exhaust leak -- yea, ours seems to do so too, and I replaced all 6 studs with brand new, and torqued to specs -- perhaps it really needed to be a bit tighter.

So best of luck...

 

The one that was in the car is surprisingly in good shape. I suspect that it was changed at some point, while the slave was not. When I get a new one in, I'll change it out, since there's no point in running the old one like that.

It was minor slippage, and it went away. I did 4th gear runs at full throttle after a 25 minute drive, and didn't notice it any more.

Remember that one of the studs on the driver's side manifold snapped in two. I figured they were welded in, but one of them came out later. I'll get new studs and replace them, too. Don't happen to have a part number, do you?

 

Oh yea, forgot about that, makes sense -- and sure, my pleasure -- here's the number: GM # 14057005 (Stud, exh pipe m10x1.5x57)(92-93) (and different than for our 94). BTW, remember my parts catalog is circa 2002, so it might have changed.

RE: slippage, I guess like brakes it needs a bit of break-in -- sounds great...

Re: master, if newer, might also explain why its shifting so great... I know ZFDOC.com recommends R&R master every other slave, so if newer, might not need to replace it afterall...