Help ASAP chatter noise after clutch work

[evolegacy]

To keep it simple, I have a 99 GT 5 speed, me and shane replaced the clutch, pressure plate, flywheel, throwout bearing, and pilot bearing, among other things. The clutch is a stage 1 from comp and the FW is a lightweight also from comp. Almost immediately I started to get a very loud metallic grinding noise coming from the transmission while coasting in gear. I'm also hearing the clutch squeal a bit as I engage it coming out of a stop. I replaced the throwout bearing with a sleeve kit one and my first guess was that it wasnt in properly, so we replaced that one once we were able to (roughly 1000 miles later) I only replaced the bearing though, and left the sleeve from the sleeve kit in place, but again I'm still having the same issue. It's been almost 4000 miles since we did the initial work and from what I can tell is that the noise is still the same but I'm starting to hear what sounds like a dry bearing while accellerating...so could be the throwout bearing perhaps? Idk anymore this has had me stressed for so long I can't think straight.

The only thing I can point out that could help solve this is that I had another friend with us who took care of the throwout bearing, but I don't think he greased the fork where it rests against the bearing (read in a hands manual that you're suppose to do this)

Outside of what I listed, we also replaced the tranny fluid, changed the clutch line to an SS, replaced the rear main seal and oil separator plate, and installed a LW crank pulley. Help would be greatly appreciated

[Huffer]

Has to be an installation issue with the TO bearing. You mention a sleeve kit. Are you talking about the TSK for the 5MT snout?

[evolegacy]

thats my guess too, and yes, the sleeve that goes over the shaft and is pushed back against the wall of the bell housing. It was meant to be used to eliminate the squeak i have at idle with the clutch engaged, and it did the trick, but then this happened. When I used the TOB from the clutch kit I got, it didnt come with a sleeve and the old one was junk (idk if that was oem or not but yes, there was a sleeve on it originally) so I left it on but the squeak is back, but its not my biggest worry atm.

I have 1 more TOB that I can swap in and this time I'll install it myself. Do you know if the retainer clips are something you can buy at the parts store or would I have to get that from the dealership? the retainer that is on it currently was meant for the TOB from the sleeve kit, which was designed differently than the OEM

[d1giPhux]

Describe the metallic grinding noise you hear a bit more.

And when does the squeal occur?

You know whats weird about all this. I got the SAME issues on my car after having the TSK kit installed on my car, and lightweight flywheel.

The squealing happened initially, and was definitely a TOB related issue, but then it went away. Now my car just grinds and sounds like a MOFO when you let off the gas and its decelerating.

I'm interested to know what you find, as my car has been doing the same friggin thing. My TOB squeal went away, but the grinding noise never has. Everything still feels okay though.

[evolegacy]

See that's exactly what mine is doing, and I've read in numorous other subie forums saying the same thing, and they all have really bizarre answers, best ive heard so far was someone saying it was from jacking the car up using the rear diff and causing the rear subframe bracket mounts to bend, making it hit the driveshaft. The squeal occurs when I'm starting to drive coming out of a stop, as my releasing the clutch pedal you can hear it for a few moments as if the clutch pad is slipping between the pressure player and the. Flywheel.

Something I noticed today is the noise volume seems to fade in and out but idk why. I start driving, its quiet, once the car warms up its very loud, but randomly after doing a lot of highway driving, when I get back onto small roads the volume drops...then after driving in city for a few miles it kicks back up. I made an audio clip (shit quality) that ill upload later

[Huffer]

The TOB on the TSK kit is MUCH bigger than the one without - like a stock Exedy one. You can't use the TSK sleeve without the TSK TO bearing... and the clip that's used on that bearing is specific.

If you went with a non-sleeved TO bearing, then take the sleeve off, and use the correct clip.

[Reason]

You can't use a bearing that has no sleeve like a stock OEM, it doesn't fit. The bearings on the TSK1 were bad and told him to send it back. The second throw out bearing used came with a OEM replacement kit. BUT this once came with a sleeve as well. So the only thing changed was the bearing. That one used spun a lot better than the noisy and loose tsk1.

I don't believe anything is wrong with the second throw out bearing and its install as it should now. The noises is either the flywheel, transmission or the noise has always been there but you never noticed it. There's less dampening on this whole set up now. So noises will be louder.

[evolegacy]

ya but we had to use the same clip from the TSK on the new TOB, remember? plus we didnt grease the forks where they contact the bearing >.<

[Reason]

The bearing doesn't spin on the contact point on the fork. And that sleeve is the same thing. You are just hearing noises that were there before, but just amplified due to the lost dampening mass on the crank pulley and flywheel.

[d1giPhux]

My squealing was from the TOB. It would do it when I pushed the clutch in.. however, it went away after some time.

I also hear all sorts of metal grinding type sounds now too.. but it hasn't blown up my trans yet. YET. What weird is.. after having my rear diff replaced (it mangled itself), my car now makes MORE noise then it did before. Not sure why that would be, but I'm guessing that its because the trans is making more noise now.. weird stuff! Wish i knew more about it really.

[Reason]

Well the sound was there with the first TOB and its there after the second TOB. That sound supposedly came after we did this work. Everything was double checked the second time. This is a noise that was there before and is now amplified.

[evolegacy]

so got fd up trying to figure it out myself and went to a dealership to have someone do a road test on it. The shop foreman took it for a spin and immediately started to comment on how bad the clutch felt (mind you, its a new one >.>) then when the noise started up he said it didnt sound like anything internal but due to how the clutch pedal felt and how the car was shifting he thinks that whoever did the work (I played the part of the dumb car guy just to see what he says) didnt install it correctly or didnt torque it down properly, specifically the pressure plate or the TOB. So once i can get the chance to get shane to let me use his hoist again (sry bro~!!!!) or save up enough for one I'll get this settled once and for all....hopefully

[Bookem]

Post back up with what you find, I have the same deal going on but it's getting worse and I will be pulling it all apart soon.

[subyL92]

On my 98 leggy outback i just replaced the clutch with exedy stage1 clutch kit...
New clutch plate, pressure plate, t.o. bearing, and pilot bearing...
Now my clutch pedal gets really spongy at high rpms and no pressure until you hit the grab point at 3in off the floor...
And now at idle it makes that squeek noise until you depress the clutch..
Note that the clutch feels perfect at idle and low rpms..
Hydraulic.problem maybe?

[evolegacy]

Post has been dead for over a year. Never found out the problem but I don't own the car anymore either