Clutch problems?
Le Mans Master
Joined: Aug 2015
Posts: 6,125
Likes: 2,000
From: St. Charles MO
So the brake test tells us that it only happens when the drive train is loaded, but the brakes load the differential and u-joints as much as they do the clutch. So I don't think that really isolates anything. But if you're pretty certain about the location of the sound, then hopefully you're right. I also hope it isn't something in the transmission! On the plus side, it's pretty rare that the ZF6 has a mechanical failure like that.
Melting Slicks
Joined: Jan 2008
Posts: 2,054
Likes: 120
From: AZ
.No matter how good a description, a noise is very difficult to understand what it really means. The good news is that you probably needed to do this part anyway. A clicking might be heavy or lighter in nature and may relate to U-joints or even those pesky wheel bearings, including the washers, with noises that can be described as clicks, under load.
Thread Starter
Heel & Toe
Joined: Oct 2016
Posts: 21
Likes: 0
Sorry for the late reply but yes I understand that when I did the brake test it loads the whole drivetrain including the rear end and u joints. But what I was getting at is that I could for sure hear the noise from the transmission area but we'll see. My clutch and new u joints should be in soon and I will post back and let y'all know if it fixed it. Fingers crossed lol
Melting Slicks
Joined: Jan 2009
Posts: 3,482
Likes: 196
From: folsom california
with that kinda mileage you gotta believe everything is at, or near the end of it's useful life.
in my case, one of the first rehab's was replacing the six u joints and since the drive shaft and half shafts were out , it is an easy task to separate and drop the differential from the bat wing...when you do that, all should be revealed as far as drive line issues...
a huge mistake, especially with these cars is "fixing" one drive line issue and then putting everything back together only to find ...nope that either wasn't it..or it was only part of the problem.
on that note, BEFORE reinstalling the trans, leave the pilot bearing tool in place and have someone operate the clutch so you can visually verify that the clutch is indeed releasing and that there is no mechanical interference between the clutch fork, pressure plate, etc.
one other thing, now is the time to inspect and probably replace all the rear suspension bushings ....bad, worn out bushings and rear tie rod ends can generate a lot of noise, which may or may not be contributing to the issues you are experiencing.
in my case, one of the first rehab's was replacing the six u joints and since the drive shaft and half shafts were out , it is an easy task to separate and drop the differential from the bat wing...when you do that, all should be revealed as far as drive line issues...
a huge mistake, especially with these cars is "fixing" one drive line issue and then putting everything back together only to find ...nope that either wasn't it..or it was only part of the problem.
on that note, BEFORE reinstalling the trans, leave the pilot bearing tool in place and have someone operate the clutch so you can visually verify that the clutch is indeed releasing and that there is no mechanical interference between the clutch fork, pressure plate, etc.
one other thing, now is the time to inspect and probably replace all the rear suspension bushings ....bad, worn out bushings and rear tie rod ends can generate a lot of noise, which may or may not be contributing to the issues you are experiencing.
Thread Starter
Heel & Toe
Joined: Oct 2016
Posts: 21
Likes: 0
Well I got the u joints in the driveshaft and the clutch showed up and I ordered the wrong one. I got a spring hub disk because I didn't think it would be an issue with the flywheel I have but I was wrong so now I'm waiting on the unsprung disk to get here. If this doesn't fix it my next place will be the washers that everyone talks about. In the meantime I sorted out the stereo. This car may have some running issues but it has one hell of a stereo in it. Whoever had it before put a full Rockford fosgate system in it.. Highly recommend them if anybody is wondering. But thanks for the comment about replacing the half shaft u joints I think im gonna run the ones in there till I know for sure there done
Thread Starter
Heel & Toe
Joined: Oct 2016
Posts: 21
Likes: 0
However I did look at all the tie rod ends and bushings when I initially discovered the noise and every suspension related part honestly looks pretty good. No movement or dry rot of the rubber anywhere. I assume most of it's been replaced because it looks really good for the age
Le Mans Master
Joined: Aug 2015
Posts: 6,125
Likes: 2,000
From: St. Charles MO
Thread Starter
Heel & Toe
Joined: Oct 2016
Posts: 21
Likes: 0
You have a single-mass (solid) flywheel, right? The sprung hub should be what you use with that. Are you sure it's a single-mass flywheel? It doesn't look like this, does it? If so, then it's the OE dual-mass unit that requires a solid disk. Were you able to find a brand and part number on your flywheel?
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Le Mans Master
Joined: Aug 2015
Posts: 6,125
Likes: 2,000
From: St. Charles MO
- Can a DMF safely be resurface? I am assuming you followed through on your plan to do that.
- The DMF has moving parts inside it. Is it possible that the noises you were hearing are explained by something breaking inside of your flywheel?
Thread Starter
Heel & Toe
Joined: Oct 2016
Posts: 21
Likes: 0
Okay it's been about 3 weeks but I finally got the right clutch in and got around to installing it. All told work time took me 8 hours to do everything. Now the results:
1. The new clutch is great, it is smooth engaging all around pretty good.
2. One thing I found interesting is that there is virtually no noise when the trans is idling in neutral now vs before it was just a loud transmission. Why that would've changed with just a new clutch is beyond me but I'm not complaining.
3. The original noise is still there..
So at this point in pretty convinced it's those Teflon washers people mentioned because it makes the noise when I'm accelerating hard and not when I'm just cruising around. But doesn't seem to be a major deal right now so I'll prolly wait a little while on it and just drive it.
Thanks again to all those who've helped!
1. The new clutch is great, it is smooth engaging all around pretty good.
2. One thing I found interesting is that there is virtually no noise when the trans is idling in neutral now vs before it was just a loud transmission. Why that would've changed with just a new clutch is beyond me but I'm not complaining.
3. The original noise is still there..
So at this point in pretty convinced it's those Teflon washers people mentioned because it makes the noise when I'm accelerating hard and not when I'm just cruising around. But doesn't seem to be a major deal right now so I'll prolly wait a little while on it and just drive it.
Thanks again to all those who've helped!
