Clicking noise felt in clutch pedal

[Ultramaroon]

Originally Posted by RToyo86

Good chance I'll be swapping that slave back in. Even with the Mtec assist spring the pedal is still so very very light.

Definitely a good mod and cheap!

Wait... Did you reinstall the original when you changed the clutch?

[RToyo86]

Originally Posted by Ultramaroon

Wait... Did you reinstall the original when you changed the clutch?

Forester slave was already installed when clutch was done. I swapped to OEM after you asked me to pull the fork against the slave. Just wanted to get baseline and eliminate variables.

[Ultramaroon]

Originally Posted by RToyo86

Forester slave was already installed when clutch was done. I swapped to OEM after you asked me to pull the fork against the slave. Just wanted to get baseline and eliminate variables.

Ah. It would've explained the higher engagement. With greater mechanical advantage of the original slave cyl. comes that wider arc of vague in-between-ness.

[norcalpb]

My clutch is doing the same thing but Im hoping it’s not my 3rd throw out bearing saying to me:

[RToyo86]

Clicking noise has since gone away oddly enough.

New issue has appeared now that I'm getting comfortable pushing the car a bit more, higher RPM shifts into 4th-5th gear grind a bit. Over 4000rpm.

Tested on highway downshifting from 6th to 5th at 125kmh/75mph or so and would grind. Did it again around 100kmh/60mph and it shifted smoothly into gear.

I guess I'll be pulling the trans again soon to see if I can find anything obvious going on. Planning to lube some stuff on the fork/bearing side some more but I doubt that will resolve things.

Maybe realigning clutch is in order. Last I installed it the alignment tool moved freely and torqued clutch /pressure plate to 14 pound feet as per a thread on here with specs.

[blsfrs]

Originally Posted by RToyo86

Clicking noise has since gone away oddly enough.

New issue has appeared now that I'm getting comfortable pushing the car a bit more, higher RPM shifts into 4th-5th gear grind a bit. Over 4000rpm.

Tested on highway downshifting from 6th to 5th at 125kmh/75mph or so and would grind. Did it again around 100kmh/60mph and it shifted smoothly into gear.

I guess I'll be pulling the trans again soon to see if I can find anything obvious going on. Planning to lube some stuff on the fork/bearing side some more but I doubt that will resolve things.

Maybe realigning clutch is in order. Last I installed it the alignment tool moved freely and torqued clutch /pressure plate to 14 pound feet as per a thread on here with specs.

It sounds like your 5th gear synchronizer could be going bad. If it were a clutch problem, you would notice it with other gears. Does it matter how fast you shift into 5th? Are you unconsciously doing something different with with the 4th to 5th and 6th to 5th shifts?

[RToyo86]

Originally Posted by blsfrs

It sounds like your 5th gear synchronizer could be going bad. If it were a clutch problem, you would notice it with other gears. Does it matter how fast you shift into 5th? Are you unconsciously doing something different with with the 4th to 5th and 6th to 5th shifts?

I tried shifting into 6th to 5th couple different ways when I noticed it on the highway. Some shifts would feel worse than others but throws felt pretty consistent. Even tried a double clutch and rev match at best as possible and still got a little crunch going into gear.

Just did a quick drive from the gym and noticed weird feel in third so I added some length back o the pedal and will see if that does anything.

[RToyo86]

Another update after adding some length to the pedal.. the issue got better. Made one more adjustment at the house last night, and was able to drive it to run errands just now. Pedal is considerably longer than before probably closer to stock engagement length(no idea where that is anymore) and car went into 3rd-4th at high rpm on the onramp and 6th-5th much smoother.

The grabbing point feels like it has more meat compared to how it felt when that tick/bind in the pedal was present... Absolutely perplexed on this but for now everything seems to be working as advertised.

[RToyo86]

Spring/summer update. Noise is back. It went away during the winter, but noticed it a week ago and today it's been particularly bad.

The shift issues I had have been resolved by swapping out amsoil for redline.


Stuck my phone next to the slave to get idea on noise. I booked a bunch of vacation, and plan to pull the transmission again and take a look. Noise only happens when engaging the clutch.


https://youtube.com/shorts/5_uK5OA5u...WwCXdPkDLbXz7E

[Ultramaroon]

I still suspect pressure plate failure.

[RToyo86]

Forgot to update this, I tore the transmission out about a month after my last post, and regreased the TOB, clips and put a thin layer on the face of the TOB where it touches the pressure plate. Noise has not returned since then.

My best guess/theory was improperly set clutch pedal length and not enough grease on individual parts. I had it set quite long and my theory is that the thicker BG TOB hit the end of the bearing cover snout and lost all the grease in the groove.

[NoHaveMSG]

Originally Posted by RToyo86

Forgot to update this, I tore the transmission out about a month after my last post, and regreased the TOB, clips and put a thin layer on the face of the TOB where it touches the pressure plate. Noise has not returned since then.

My best guess/theory was improperly set clutch pedal length and not enough grease on individual parts. I had it set quite long and my theory is that the thicker BG TOB hit the end of the bearing cover snout and lost all the grease in the groove.

Weird, they looked about the same size when I compared them.

[RToyo86]

Originally Posted by NoHaveMSG

Weird, they looked about the same size when I compared them.

I didn't take exact measurements so you are probably right.
Lesson learned on making sure TOB and related components are greased enough.

[RToyo86]

Noise is back after a track day
Going to see if I can get some grease onto the TOB with trans installed using hole where the fork is. Worst case trans comes out again to be lubed.
Also observed the verus fork makes a noise when moved left/right. Not sure if that's normal, I've never payed attention to that until now.

Edit: pulling the trans to inspect the snout. BG wants to see it for any potential abnormal wear.