Toyota GR86, 86, FR-S and Subaru BRZ Forum & Owners Community - FT86CLUB - View Single Post - FR-S Extreme Clutch Problems

mhansen146 · 01-30-2020, 07:05 PM

I have issues similiar to the op, atleast in regards to noises. Im very curious as well if this was ever resolved.
My car has 35000, 2015 bought second hand (my 2013 was killed by a silverado unfortunatly).

All the info I can think of: early days: metallic metal on metal noise, more common on cold starts, but sometimes all the time. Light pressure on clutch pedal stopped the noise of the time. Could also be heard when driving light throttle on decel (off throttle engine braking). Suspected tob, replaced it and entire clutch, all oem parts (everything seemed fine tbh, including bearing). Came back quickly. Very itermittent. When clutch fork is forced AWAY by hand from pp (compressed against slave), sound gets worse. Most of the time.

Today: car has developed starter issues. It occasionally had a crappy engagement/mesh type sound early on, but has gotten worse, when it happens. Also intermittent. Sometumes starter only spins and only catched occasionally. Again, this is itermittent. Sometimes zero drama. Seriously... i replaced the starter with a clean low mileage starter. Teeth on mine badly worn, almost machined off a few mm deep on pinion (will post a pic soon). New starter installed, twrrible grinding metallic noise all the time. Took off and reinstalled original. Teeth on new starter chipped.

More observations: when car makes metallic noise, starter works fine, pushing back and forth on clutch fork at the slave changes intensity. When starter is acting up, metallic noise is rare, hard to replicate is clutch fork, and when car is revved, i get a rattle from that area. Rattle is only present when starter is acting up. Its a heat shield type rattle.

All work done by me (since purchase), all with factory parts, all torqued to oem specs. Will post videos and pics.

I believe trans was replaced at some point as it had a 2016 build date on it

I think these issues are connected. So far im totally drawing a blank, but im thinking warped flywheel maybe? Clutch is very smooth, no engagement issues, chatter, tob feels great. I did have flywheel resurfaced..

Ideas? Its driving me insane!

01-30-2020, 07:05 PM	#16
mhansen146 Junior Member Join Date: Nov 2013 Drives: '15 FR-S '85 4WD Tercel '95 Trooper Location: Tempe Posts: 6 Thanks: 0 Thanked 7 Times in 5 Posts Mentioned: 0 Post(s) Tagged: 0 Thread(s)	Non-throwout bearing related intermittent metallic grinding I have issues similiar to the op, atleast in regards to noises. Im very curious as well if this was ever resolved. My car has 35000, 2015 bought second hand (my 2013 was killed by a silverado unfortunatly). All the info I can think of: early days: metallic metal on metal noise, more common on cold starts, but sometimes all the time. Light pressure on clutch pedal stopped the noise of the time. Could also be heard when driving light throttle on decel (off throttle engine braking). Suspected tob, replaced it and entire clutch, all oem parts (everything seemed fine tbh, including bearing). Came back quickly. Very itermittent. When clutch fork is forced AWAY by hand from pp (compressed against slave), sound gets worse. Most of the time. Today: car has developed starter issues. It occasionally had a crappy engagement/mesh type sound early on, but has gotten worse, when it happens. Also intermittent. Sometumes starter only spins and only catched occasionally. Again, this is itermittent. Sometimes zero drama. Seriously... i replaced the starter with a clean low mileage starter. Teeth on mine badly worn, almost machined off a few mm deep on pinion (will post a pic soon). New starter installed, twrrible grinding metallic noise all the time. Took off and reinstalled original. Teeth on new starter chipped. More observations: when car makes metallic noise, starter works fine, pushing back and forth on clutch fork at the slave changes intensity. When starter is acting up, metallic noise is rare, hard to replicate is clutch fork, and when car is revved, i get a rattle from that area. Rattle is only present when starter is acting up. Its a heat shield type rattle. All work done by me (since purchase), all with factory parts, all torqued to oem specs. Will post videos and pics. I believe trans was replaced at some point as it had a 2016 build date on it I think these issues are connected. So far im totally drawing a blank, but im thinking warped flywheel maybe? Clutch is very smooth, no engagement issues, chatter, tob feels great. I did have flywheel resurfaced.. Ideas? Its driving me insane!