HELP!!! Im scared - gear box/thrust bearing noise

[courtz1976-2dr]

Hi there Everyone,

Please help me to stop having the rather major panic attack that I am having at the moment, heres the story

Just finished putting back together my engine/gearbox after install of NEW gearbox, clutch kit timing chain etc.

When started with clutch depressed no noise, and everything sounds sweet, BUT when I let the clutch out I am getting a noise that sounds like the thrust bearing but not too sure - this is a brand new gearbox and the noise is concerning - is it just that everything is "dry" (the gearbox shipped dry) and the oil has not made it's way up to the gearbox yet or is the thrust bearing suspect (is brand new also) I am going to try selecting a gear and see if that is ok but I am freaking, if htis engine has to come out again

PLEASE HELP


UPDATE

Just tried selecting gear and releasing clutch a little the noise is not really there car wants to move but dont want to drive yet. the noise is much more pronounced in neutral with clutch let out. I am pissed it sounds like this thrust bearing new is dodgy I REALLY do not want to pull this engine out again any suggestions????

[h100vw]

Is it a VR6, you talk about timing chains. The engine doesn't have to come out to remove the gearbox. Have you driven it or is it on axle stands?
Gavin

[courtz1976-2dr]

Hi Gavin,

Yes VR6 - sorry I wasn't more specific - I have had the engine split and whilst out did the timing chains, they sound fine. At the same time I have fitted a new o2j (car is mk3 golf) flywheel clutch pressure plate and new thrust bearing - the gearbox came with new lever etc.

I am yet to drive it as this is the first start after reassembly. here are the symptoms

neutral clutch depressed - no noise
" Clutch out - noisy but of a tick tick tick before full stroke and then fairly noisy
1st selected clutch in no noise, slowly let out, can hear clutch engaging and biting car moves but have not driven yet due to concerns above. no noise but have not released clutch full yet.

I really hope that a new sachs bearing wouldn't be the cause and I was anal about the install.

Thanks for any help

[h100vw]

The tick tick thing has caught my eye. The throw out lever on the mk4 box, did you have a look at it before it went in? I had an A3 and the lever cracked and split. The result was that the edge of it was bent far enough to touch the rivets around the edge of the clutch cover.

A new lever was $40 from VW. It's the same part on the 02A, although VW have uprated it as the part number has been superseded.

Read your post again and don't think it's the lever, mine was noisy with the clutch in, not out. The bearing being noisy would be an irritant but not fatal.

I think it could be a bit of drag in the clutch. I reckon I would drive it up the road if it were mine and see what the score is then. Or jack it up and run the engine and go through the gears on stands.

Gavin

[courtz1976-2dr]

I just managed to go for a small (very small) drive first of all couldn't get reverse (shifter alignment) then no brakes (wasp nest if vacuum hose) but noise is stil there only a little bit of noise when pressed in but sounds really bad released . I really cant understand what this may be any ideas. if it was binding then it would make noise when under load it. I removed the clutch slave cylinder to have a look see lever moves freely and is brand new (but is mk4 and came with box is there any difference???) still makes the same noise .could it be binding on the gearbox sleeve but this should all be the same. any ideas would be appreciated.

Cheers and regards,
Courtney

[courtz1976-2dr]

Have pulled the gearbox out again and have discovered that it is WAY worse than I thought. Pressure plate studs are actually chewing into the gearbox housing and thank god I didn't drive it. The amount of damage is slight but it has worn about a 0.2mm arc into where the output shaft end cap is on the gearbox, exactly the same area that was obliterated in the previous gearbox.

Now is it possible that the crankshaft is moving enough to cause this ie endfloat is there any "tin" bits that go between the gearbox and engine block (they weren't there on disassembly)

What would be the problem to cause enough movement in the crankshaft for this to happen - ie clutch depressed no noise clutch let out...well you can imagine the sound. This engine has only done 90.000 KM and had no indications of any main bearing wear.

Everything from the crank shaft outwards was new, now possibly cactus. please anyone with some advice.


Cheers and Regards,
Courtney

[h100vw]

Hey mate, can you take us a picture of the damage please?
Gavin

[courtz1976-2dr]

Here goes, I hope you can view them. UPDATE I have been comparing the old (LuK) pressure plate vs the new (Sachs) pressure plate and the studs on the sachs sit out (more proud) by about 1.1mm when measure from the mating surface to the full height of the studs. I have also used a lever at both ends of engine to see if there is any play - maybe .2mm when levering back and forth it can be felt at the end of the levers (between front pully + flywheel)

Anyways here are the pics


https://picasaweb.google.com/1157007...92281744789122

you can see where the studs have gouged out a bit of the gearbox casing



https://picasaweb.google.com/1157007...92264305084034

Another angle

What do you reckon?? I am not impressed if it is the sachs plate being a little bigger, hard to tell what the clearances are like inside the gearbox..

Thanks.

[courtz1976-2dr]

HI there everyone,

can someone give me a howto to check end float on the vr6 and where I need to check it from ie between what journal or bearing. I have done a search but to no avail. It is the only thing that I can think of... Matt I know your out there somewhere have you had any experience with the above issues.

Cheers and Regards,
courtney

[Jmac]

Hi, just having a read here. If it were the bolts causing that it would rub all of the time. Did you sit clutch and pressure plate side by side mirror image etc to check heights? Only really seen that with the 020 gearbox as there is clutch variants, sounds like could be misaligned, did the pressure plate sit snug in the dowels? Doesnt take much to misalign them on install
Cheers
Jmac