What's this noise after Troopy clutch replacement?

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Hi John
That sounds exactly like my 80 i replaced the clutch kit with an one and the noise was still there. I was told it was the gear box so i recond it and put a genuine clutch kit in it and it is still the same.It's been 3 years now all works well but the noise is still there. Apparently the gearbox was ok.
I have learnt to live with it. (Its a diesel thing).

John,
it sounds like it is rubbing on something.
a quick guess would be the throw out bearing is rubbing on some uneven pressure plate fingers. which would also mean that the bearing isn't getting pushed back enough from the return spring (on the outside of the bell housing.

and when the clutch is pushed into the fingers they are running true due to the throw out bearing flattening them.

the lighter clutch feel would also be due to the fingers not being as strong as the OEM.

thats my first guess. any other thoughts?

Hi John, had something similar on my old 1982 Jackaroo, but usually after/during a long trip. It would gradually fade away from constant city use, and come back after a couple of hours on the highway?!
The transmission mechanic said it was gear rattle caused by the springs in the clutch plate being too heavy. Between the clutch friction material (outer part of clutch plate) and the gearbox input shaft spline at the centre of the clutch plate, there are a series of springs that serve to absorb the uneveness caused by the power strokes of the engine (ie. the engine by it's nature doesn't supply constant power but only on combustion which means the power is produced in a series of 'bursts' , each 'burst' corresponding to the power stroke of one of the cylinders, each in turn (ie, for a 4 stroke 6 cyl, you will get 6 'bursts' for each 2 engine revolutions - think of a pushbike where you're only pushing down on the pedals - in that case (2 stroke!) you get two 'bursts' of power for each full revolution of the crankset). If these said springs are too stiff, you get gear rattle.

However, having listened to the recording, it's unusual to hear this sound without load on the gearbox/drivetrain (ie. when you are just idling, as recorded). I also wouldn't expect it to be *that* noticable. Generally, if you get noise when releasing the clutch in neutral it indicates that the bearing on the gearbox input shaft needs replacing.

BTW: the sound of that diesel engine idling is music to my ears (at least until you released the clutch!).

Phoenix Owners Group
A new clutch always gives a lighter pedal. Is due to more leverage applied by the diaphragm fingers on the pressure plate as the clutch plate is thicker when new

John.

Try checking the free play of the pedle and the throw out lever.

I listen to the WAV. and it is load, have you taken it to chutch and gearbox place for them to listen?

And by the way why was the clutch replaced? My 2003 Troopy has done 145000 km now and all is fine she weights in at 3.5 tonne all the time and we sometimes tow a caravan beit only small.

Regards

Richard

I take it the noise was not present prior to the clutch replacement. If this were the case, I'd think it rules out the gearbox as the source.

If the noise is coming from the release bearing contacting the diaphragm spring (Toyotas have no freeplay) then it should go away with very light pedal pressure (before the clutch is released), and is unlikely to happen with new parts.

An alternative cause is that the clutch centre was damaged during installation by having the weight of the gearbox hanging off it. If this were the case, the noise would not go away until the clutch is fully released.

Sounds like the gearbox rollover clatter to me, my old 80 series diesel did it too. I had the cluth and gearbox replaced/ rebuilt and it was still there.
Maybe they moved or removed some sound proofing around the transmission tunnel and this is allowing you to hear it more.
Basically it sounds normal to me.
Listen to any manual truck (that isn't fitted with a roadranger gearbox) and it will sound the same as you push the clutch in and out.

Cheers
Dave

In 1998 a brought a 1993 troopy. In the test drive there was a bit of shudder/chatter when changing gears, the owner said its cause your not use of the vehicle, he also said that it recently had the gearbox overhauled by Bigrock Toyota. I brought the vehicle. After awhile an oil leak developed at the rear of the motor so I put it in to have fixed which meant the gearbox etc had to come out. The mechanic rung me and asked who put the clutch in I told him and asked why, he replied that they put it in back to front. I've never had a problem since... touch wood.