phocup

Sorry ahead of time for the long post, but I wanted to provide as much detail as I can.

So background .. I just swapped a 99 motor into my 93 donor exocet. Motor was bought used on CL but compression is good. Seems to run strong.
BUT .. I've been tearing my hair out for a few weeks trying to hunt down this 'banging' noise whenever I press on the clutch.

Pulled the transmission TWICE already since I put the new motor in.

Initially installed motor with used 949 pressure plate ( unknown mileage ), new clutch plate, new pilot and timken throw out bearing, and a used Fidenza lightweight flywheel ( about 200 miles ), my original 5 speed.
I noticed this issue immediately while prepping for first test drive so didn't drive it, but instead pulled back into garage to 'fix'. Gear shifted fine. Clutch felt fine. Not grabby of slippery. Just really bad noise.

First time tranny pulled I replaced it with a new 5 speed ( original was leaking oil where there was no seal ), all new seals in new tranny, new throw out bearing, and made sure I greased everything properly in reinstall.
This video is me checking the first new timken throw out bearing in old tranny before replacing it with another new timken throw out bearing and new tranny.

Immediately after install, I had the same noise issue. As a hail mary I replaced the clutch slave. Bled the system and greased the tip. Nope .. didn't fix.

Second tranny pull was required. I figure it might be the used clutch, so I bit the bullet and ordered a brand new 949 kit. Arrived yesterday and in the car today. This time I pulled the flywheel as well and replaced the pilot bearing with new SKF bearing and 949 throw out bearing and well as used the brand new clutch pp / disk. Installed and greased same as the first and second time.

Nope. Just touch of the clutch pedal I already heard the sound. I could even hear it when I lightly actuate the lever connected to the throw out bearing with my finger instead of using the clutch slave hydraulics.

Any ideas ?! I don't think there's another parts I could throw at it to test beside for a new motor.

gooflophaze

I seem to recall a thread on my local forum - there's a difference in the height of the ***** the clutch fork pivots on between NA6 and NA8. I think the local members issue was unable to get it into gear with a mismash of hydraulics and transmission bits, not just noise though.

phocup

Thanks. I guess the lack of response is a bit expected as this is a strange issue .. which I now believe is crank walk.

Measured my end play tonight to about .012" or .3048mm. The service bulletin PDF says "If end play is 0.3mm or more, proceed to STEP 3 - replace engine". That's REALLY borderline. However, the symptom described on that PDF "A rattling noise may be heard from the engine when depressing the clutch or when revving the engine in neutral" also matches my issue. Also it sounds just like this other video ( ).

I'm going to start looking for a new motor. That's the last part I could swap out to test it anyways.

ryansmoneypit

iTrader: (6)

At least you sound like your in good spirits about it.