New 03/04 Clutch IN GT Rattle

97predator · Sep 5, 2009

Rattle from New Clutch in First Gear

So I had a new clutch put in recently. It is the 03 Cobra clutch in a 2002 GT. Had the fly wheel resurfaced, new clutch fork, pilot bearing, and throw out bearing installed. I am a little over five hundred miles so the clutch is about broke in.

I am getting a "clinking-rattling" noise when I shift in to first gear. As the clutch fully engages you hear the rattle and klink start. It sounds like somehting metal is hitting something that is spinning ever so slightly. Like--tink, tink, tink, klink. What is odd though is that as the car is run and gets rolling for a few minutes, the noise gets less and less pronounced and eventually goes away more or less. What is going? Should I be worried?

I think maybe I need to get a firewall adjuster and new clutch cable...? The car has the original cable and quadrant, could the clutch fork not have tension on it and be rattling around?

Any help is appreciated. I wanted to do some research before I freaked out and took the car back in to the shop pointing fingers.

97predator · Sep 6, 2009

Bump.

302GTS · Sep 6, 2009

Was wheel bearing grease packed into the new throwout bearing, the fork, the pivot ball, and the input shaft? If it wasn't, a throwout bearing failure can occur VERY quickly. I had one fail 1,500 miles after putting a brand new one in.

97predator · Sep 7, 2009

I would assume they did. What is throwing me is that the sound goes away after a few minutes of driving.

What else could be causing the sound?

tonytaylor85 · Sep 7, 2009

I may be confused- as your foot comes off the clutch it clinks as when leaving a light. And after you are in gear and underway it stops?

97predator · Sep 7, 2009

Exactly, the klinking occurs as the clutch is let out. It literally sounds like something loose rattling around. Once the car is moving it doesn;t make the noise anymore. When I go into second sometimes it makes the noise. But after five minutes of driving the noise dissapears all together and doesn't come back.

302GTS · Sep 7, 2009

When my throwout bearing failed after not using grease on the replacement, the noise/grind feeling went away after about 5-10 minutes.

tonytaylor85 · Sep 7, 2009

302GTS said:
When my throwout bearing failed after not using grease on the replacement, the noise/grind feeling went away after about 5-10 minutes.

I see what you did there!
Mine is squeaking now. long story.

seths99cobra · Sep 7, 2009

i have a comment on this my car is doin the same thing but i found out what my problem is. the shift fork cover on the outside of the tranny doesnt fit in the grooves right so it rattles for a few minutes or until i put my foot on the pedal then it stops. so try this before you go taking the tranny out again and spending more money jack up one side of the car while its running and put your had on that cover and see if it stops. thats what mine does and it sounds like yours is doin the same. hope thats your problem something simple

97predator · Sep 8, 2009

I will give that a whirl and let you know. I fired the car this morning and i rattled at first, then stopped by the time I hit the end of the street. I don;t think it is the TOB because it is not a grind or a squeel. It's a mechanical or impact sound, not one due to friction.

I will check the shift fork cover as suggested. Would a loose clutch cable be a possible cause of the noise also?

97predator · Sep 21, 2009

Ok, so the noise is still there.

I checked the shift fork cover, secure
In neutral no whine, so not the TOB(new)
Engagaed, no noise, so not the pilot bearing(new)
No noise from the tranny

To describe the sound, it sounds like somthing hitting something and grabbing. Sometimes a little "tink, tink" as the clutche engages. Sometimes a bit louder, and sometimes something hits hard enough its more of a knock and you can feel the impact. When I hit a pothole or harsh bump sometimes I hear a noise also.

I'm guessing there is an issue with the engagement point or the clutch fork itself. I did not put in a new clutch cable or get a quadrant/firewall adjuster. Could a slack clutch cable be a problem? Can I adjust the factory engagement point to see if that eliminates the problem? Again the problem occurs during engagement and ends once fully engaged. What could be hitting what?

97predator · Sep 24, 2009

Anyone? Help?

Also, when the car is in first/second gear, and I let the car coast, then get on the throttle, the rattle happens then too sometimes...What gives? I contacted the shop that did the install and they suggested Steed's adjustable cable/quadrant/firewall adjuster. Will this resolve the problem?

97predator · Sep 25, 2009

bump.

Could it be the throw out bearing retainer?

97predator · Oct 15, 2009

Well I installed the Maximum Motorsports kit including the factory cable, firewall adjuster, and clutch quadrant. It made a signifigant difference and the clutch pedal has good feel. However, I still get the noise when I first start driving around, then after a mile or two of driving and shifts, it stops. I don;t know if this makes sense, but it seems like the clutch cable unseats from the clutch fork when the car sits, and pops back in to place once you have driven enough and made a few shifts.

When I did the install, I notice the clutch fork(new) has some play in it. It is tight within its plane of action, but moves up and down. Is their an issue with how it is mounted? Would this cause my problem?

twogts4us · Oct 15, 2009

97predator said:
Well I installed the Maximum Motorsports kit including the factory cable, firewall adjuster, and clutch quadrant. It made a signifigant difference and the clutch pedal has good feel. However, I still get the noise when I first start driving around, then after a mile or two of driving and shifts, it stops. I don;t know if this makes sense, but it seems like the clutch cable unseats from the clutch fork when the car sits, and pops back in to place once you have driven enough and made a few shifts.

When I did the install, I notice the clutch fork(new) has some play in it. It is tight within its plane of action, but moves up and down. Is their an issue with how it is mounted? Would this cause my problem?

It sounds like that's your issue. If installed correctly, there is a retaining clip to keep the fork attached to the pivot ball. If they didn't put it in properly and secure that clip, it could float a bit and rattle at will. Honestly, if you paid to have this installed, you should take it back and let them figure it out.

2002SN95MUSTANG · Oct 17, 2009

Originally posted by twogts4us
It sounds like that's your issue. If installed correctly, there is a retaining clip to keep the fork attached to the pivot ball. If they didn't put it in properly and secure that clip, it could float a bit and rattle at will. Honestly, if you paid to have this installed, you should take it back and let them figure it out.

+1 I had the same problem with my clutch release lever. When I had installed it, apparently I did not push it in far enough and it came loose and had a rattling sound to it. Also if you do not have enough tension on your cable it will allow more movement in the release lever arm. Hope this makes sense.

RedDaemon · Jul 28, 2011

:necropost: :zombie:

so i have the same issue with my car. seems that mine is a bit worse than the OP's.

i haven't had any work performed on the vehicle. this has been something that has been developing over a long period of time. started as a very faint 'chirp' when letting the clutch out. now its happening more frequently, and is even making noise while cruising when i hit bumps and shift into higher gears. i am curious if the vehicle transport service that hauled my car down south might have aggravated the issue?

2002SN95MUSTANG said:
Also if you do not have enough tension on your cable it will allow more movement in the release lever arm. Hope this makes sense.

is this to suggest that adjusting my stock cable might remedy this issue?

Lugnuts · Jul 29, 2011

I don't think the clutch cable tension is related to this noise if it "goes away". If the cable is loose or tight it will remain loose or tight with an aftermarket adjuster and quadrant. I wish I could hear it but would suggest a good inspection. Put the car on stands and pull the cover off the trans. Get a buddy to sit in the car and work the clutch and try to find the noise. You would be well served with a small bright light and a telescopic mounted inspection mirror - both cheap at harbor freight. Look for the source and look for abnormal wear indications.
Only thing that I have seen similar to this is a worn retaining clip that let the fork contact the dust cover. If this is the case, you will stop the noise with the removal of the dust cover but not fix the problem.
Check it out and let us know what you find.

RedDaemon · Jul 29, 2011

Lugnuts said:
I don't think the clutch cable tension is related to this noise if it "goes away". If the cable is loose or tight it will remain loose or tight with an aftermarket adjuster and quadrant. I wish I could hear it but would suggest a good inspection. Put the car on stands and pull the cover off the trans. Get a buddy to sit in the car and work the clutch and try to find the noise. You would be well served with a small bright light and a telescopic mounted inspection mirror - both cheap at harbor freight. Look for the source and look for abnormal wear indications.
Only thing that I have seen similar to this is a worn retaining clip that let the fork contact the dust cover. If this is the case, you will stop the noise with the removal of the dust cover but not fix the problem.
Check it out and let us know what you find.

Thanks for the input! It will take me a while to round up all the necessary tools. I am just starting out on my own so I need to buy the basics before I jump in.

Whats very bizarre is that i heard the noise come from a different spot just as i was coming home this evening. it sounds like it came from my drivers side front wheel area. i would expect the sound is traveling but now it makes me less sure of the problem

txredgt · Jul 29, 2011

Usually when sound/squealing is when pushing the clutch or letting it out its the throw out bearing. My clutch just started getting a little tougher to push right where it engages espically when the drivetrain is hot so I am starting to plan on new clutch, TOB and a piolt bearing. I don't have the time or the means to tackle this project myself though so to the shop it will go.

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