M38a1 Gearbox Noise /Grind

pockers · Post by **pockers** » Mon Aug 24, 2015 7:41 am

Ok - my clutch went on way to a show in July
Whilst there I purchased a new clutch (pressure plate & disc) , and managed to take engine out, fit new parts then engine back in (all in the middle of a field!!) old disc was well worn

however now when clutch pedal is pushed in & a gear is selected i get a metal on metal squeal/grind,
it gets worse/faster when i press accelerator.
If i select neutral it disappears.
Noise doesn't happen all the time but usually on slow stop start traffic.
It didn't make this noise before I replaced clutch

any one any ideas as to what I've done to it? or what to start looking at?
I've checked the gearbox fluid level & have topped up

4x4M38 · Post by **4x4M38** » Mon Aug 24, 2015 12:10 pm

Did you replace the throwout bearing and carrier?

A fried bearing or cratered carrier will cause that noise when
you push in the pedal.

pockers · Post by **pockers** » Mon Aug 24, 2015 5:18 pm

No didn't replace the bearing - wish I had
I seem to rember it was stuck in place- is there a technique in removing it?
Not sure what the other part is

Ps I take it there's no other way to replace the bearing other than engine/motor out?

4x4M38 · Post by **4x4M38** » Mon Aug 24, 2015 8:24 pm

Bretto has pulled the trans/transfer and left the engine in.
Might search clutch cable. It's in there somewhere.

The release/throwout bearing sits in a housing that is to the rear
of the bearing/clutch/plate assembly.

Mine was so worn out that you could grab it with your hand and wiggle
it from side to side. The sound stepping on the clutch pedal
sounded like something from Jurassic Park.

Brian

pockers · Post by **pockers** » Tue Aug 25, 2015 12:53 am

I'll have a search

It appeared ok but obviously wasn't

But I do remember it wouldn't come off

How did you actually get the bearing off?

pockers · Post by **pockers** » Tue Aug 25, 2015 1:19 am

Found Bretto , unfortunately he has over 1200 posts listed!
I have however pm'd him

Bretto · Post by **Bretto** » Tue Aug 25, 2015 6:54 am

Got your PM, I'll reply here.
It concerns me that the the noise showed up when you were done. Have you looked into the inspection hole while you are hearing this? Is the clutch being released entirely when the clutch pedal is pressed? Seems something is dragging. Does it do it only when in a gear or will it do it in neutral with the clutch released (pedal pressed)? Maybe you just need to adjust the clutch cable.
Regarding the throw out bearing, if it needs to be replaced, the tranny has to come away from engine. Be it pulling the motor, dropping the tranny or pulling the whole power train and separating them on the garage floor. No other way.
There are some parts you always inspect and or replace when you have the engine off the tranny. Clutch plate, pressure plate, fly wheel, pilot bearing, throw out bearing and carrier, clutch fork, return spring.
Brett

4x4M38 · Post by **4x4M38** » Tue Aug 25, 2015 7:08 am

Brett,
Could he have the thing in backwards? Would that cause
his symptoms? It seems easy to do.

Brian

pockers · Post by **pockers** » Tue Aug 25, 2015 7:42 am

If by thing you mean the throw out bearing then the answer is no as I left the original in place

4x4M38 · Post by **4x4M38** » Tue Aug 25, 2015 11:55 am

No I meant the pressure plate. There was a post here
but I don't remember if it wouldn't even go back together.

4x4M38 · Post by **4x4M38** » Tue Aug 25, 2015 12:07 pm

Here's the post on installing the pressure plate backwards:
http://www.willysmjeeps.com/v2/modules. ... +backwards

First thing like Brett mentioned is remove the cover from the shift
rods/tower, then the inspection cover. Park the jeep somewhere
level and block the tires.

Start it up in neutral then push in the clutch pedal and look into
the opening and try and determine when and where the noise is coming
from.

As Brett mentioned maybe ( if you are lucky) you just need to
adjust the clutch pedal free play and or cable.

Brian

pockers · Post by **pockers** » Tue Aug 25, 2015 2:24 pm

Thanks guys

Just one more thing

if it needs it - how do i get the throw out bearing off?? as im sure mine seemed stuck fast? - does it need a puller? or heat etc...
also is there a trick to putting on the new one?
ie heat etc

thanks

Post by **wesk** » Tue Aug 25, 2015 9:41 pm

Just to keep all on the correct page. You can't install the PRESSURE PLATE backwards.

Bretto · Post by **Bretto** » Wed Aug 26, 2015 5:16 am

To add to Wes post, when it says you can install the clutch disc backward, it's to say it physically can be put in either way. but there is only one way it should be installed. There is a long and short side to the splined center tube section. The long side goes to the aft end.
The throw out bearing it pressed on and off to the carrier. Sometimes packing some grease into these bearings can hush them up.

pockers · Post by **pockers** » Fri Sep 18, 2015 12:14 am

Hi
ive taken the floor plates out & taken off the inspection plate to the bell housing
The noise is definitely coming from the disc

it looks like its either vibrating or is off centre

Unfortunately i replaced it in a field at a show and it was all a bit rushed

Engine coming out again soon in better conditions

Stupid question time
if it is in backwards have i ruined it? & will i need a new one
Whats the correct torque settings for the disc?
How do i replace the throwout bearing ie how to i get the old one off & the new one on?

thanks in advance