944 clutch help

[elcap00]

I just installed a new clutch, pressure plate and had my flywheel resurfaced. Started my car and I get loud rubbing noise--almost like the disc is rubbing between PP and flywheel and then something happens------I hear a loud clattering noise like there is a nut in my bellhousing (there is not guaranteed).

I cannot figure this out---I have put a boatload of hours into this job and I am completely baffled. I need your pro insights.
Thanks
Toby---

[Steve Grosekemper]

Toby
There are so many possibilities here... That job has so many pitfalls if you haven't done it a handful of times.

I had a customer do his own clutch and dropped a nut behind the flywheel when he removed the ground cable from the bell housing. It landed on one of the ledges on the back of the block and finally fell out a few days later... very ugly noise until it broke the TDC pin of the flywheel and stopped running.

Pull the starter and the black sheet metal cover (front side) and see if there are marks on anything (Flywheel, pressure plate, T/O fork)

Does the noise go away (or get worse) with the clutch in?

Is the fork in the correct position?

[elcap00]

There are some marks on the starter ring--on the outside edge. I was almost thinking that maybe my starter is bound up. The sound (when it is bad) sounds like your holding your key in the start position for too long. Do you think a bound starter could be the issue?

Holding the clutch pedal in---does absolutely nothing for the sound. How about you come over and listen to it? I will pay you your hourly rate. I am 97% confident that the job was done correctly since I functionally did it twice.

Originally --I couldnt get the torque tube to mesh with the bellhousing so I installed the bolts until it met up. Installed the tranny only to find that the shaft inside the tube has shifted backward (cluthc disc was not aligned with the pilot bearing). I disassembled the whole shebang and with a punch guided the shaft into correct position--took off the bellhousing and realigned the disc. Then reinstalled everything-----and now I hear this really bad noise. Steve--I am on the backside of Mt Helix--c'mon over and make a quick C-Note. Give me a call if you have a minute to listen with your trained ear.
Toby--619-301-0823

[elcap00]

The fork is in the correct position--aligns with the slave cylinder--Both times when I installed the fork once installed it moved back and forth easily although--I could hear that it was rubbing on something--there was an ever so slight noise --kinda sounded like rubbing your fingernail across an old vinyl record.

since it was in---and moved freely I felt like this was probably normal.

[Steve Grosekemper]

Try this first: (With the car securely on jack stands)

1-Remove the yellow #50 wire from the starter. Jump power between B+ and #50 at the starter. Is the noise still there? If so proceed to #2

2-Pull the starter, connect the two B+ wires together and insulate. Then lower the car and push start it? Is the noise still there? proceed to #3

3-Remove the clutch assembly again... the noise will likely fall out onto the ground.


Try #1-2 ASAP! and PM me your phone number.
Really full weekend with obligations, but I might be in your area sometime tomorrow anyway.

Or you could just buy the 87 944S I am parting out! Engine is dead but the rest of the car is really nice! Even the clutch!

[elcap00]

Steve,
Thanks for your help--figure out the problem yesterday. Friday I installed the starter with both big black wires connected to large post on starter--little red wire connected to solenoid. hooking up the battery --i installed neg. cable and when I touched positive cable to terminal ---the starter engaged. I did this twice!!

At this point I figured I did something wrong with the starter wires--so I changed the configuration--installing the black wire (with red wire in shrink tube) onto solenoid.---go back to battery and installed--everything OK--start the car and get crazy noise.

After much fiddling around decided to reinstall starter with original configuration (2 large black wires on large post etc.)---this time at the battery I installed positive cable first and then negative--starter did not engage. Started car and beautiful --beautiful engine noise--nothing from the bellhousing.

what had happened is on the second try---I hooked the starter up in such a way that it was firing with the car on and the starter gear was hitting my starting ring----I cannot figure out why with the original (correct) setup that the starter engaged when I hooked the battery up neg. first and then positive. Anyhow---all done and I am moving on to the installation of 28MM rear torsion bars---this job seems like childs play next to the clutch job.

thanks for everything---once I am done with the torsion bar and firmer springs---I am going to have you (dieters) do my rod bearings and that "catch" mod.

Toby

[elcap00]

Is the head OK on the "S"? What color is the car? If red--I am interested in the doors as mine are pretty dinged up.

[Steve Grosekemper]

It is dark red, not guards red.
Engine is not good.
Water pump seized, engine overheated and then broke the timing belt.
The rest of the car is very nice.