Gearbox rattle- i think i've got a serious issue here (vid)

[u mad?]

Ok i installed my exedy stage 2 about 700 miles ago, felt fine, really good actually. Now today, im just driving along normally, i notice when i change gear there is like a wurring/ buzzing sound, got worse and worse. when i got home i let the car idle as i listened for noises, and there is a very noticeable rattle:


http://www.youtube.com/watch?v=ytUK3jve4pY&feature=youtu.be



To me it sounds like a flywheel bolt has come loose, or maybe even a pressure plate bolt, but that would baffle the fuk out of me as i torque all bolts to oem spec and in the star pattern. i even used loctite red and i thoroughly cleaned the bolts before i installed them.



NOW- this very well may be the reason its fuked if it isn't the bolts loose--- i recently changed the fluid when i did the clutch install with honda mtf. i over torqued the drain bolt and cracked the housing slightly and threaded the hole. so i cleaned as much metal out that i could and used this stuff called thread repair, a loctite product, to repair the thread, and a product called quick steel to repair the crack. It seemed to have worked fine, didnt leak at ALL.

Im thinking maybe the alloy has gone through the box and completely fuked it.

Any input would be much appreciated, im pretty down about this, so many problems with car lately.


ps- Also i haven't launched it, flat shifted, or even raced anyone since i've done new clutch, only a few pulls, nothing abusive. No crunches or miss shifts ect.

[bennjamin]

Prob a tooth on the pressure plate has failed , or a spring or two in the disc itself has popped out.

[u mad?]

Prob a tooth on the pressure plate has failed , or a spring or two in the disc itself has popped out.
I will neck myself if its the clutch. 'when diy go wrong' lol

[bennjamin]

Did yourself ? Did u hold the disc inline with a input shaft tool as you properly torqued the pressure plate bolts? Etc etc

[u mad?]

Did yourself ? Did u hold the disc inline with a input shaft tool as you properly torqued the pressure plate bolts? Etc etc

yes i did myself.

Yes i used a alignment tool that came with the clutch.

[bennjamin]

Just checking babe.

Rereading what you said - you mean the standard 17mm fill hole on the side of the diff ? This sits right on the diff - check it isn't interfering in anyway - I'd drop the box as soon as possible and recheck for obvious wear or loose bits on the clutch parts- then consider opening up the box and see what happening

[EKVTIR-T]

put a long screwdriver against the gb casing with car running

you can hear very clearly using this method,like so

http://s23.postimg.org/c9aks70wr/Diagnosing_Cylinder_head_noises_with_screwdriver.j pg

also drop the mtf using coffee filter asap and see what comes out





obviously gearbox out needs to happen but for now I'd do those..

[u mad?]

Just checking babe.

Rereading what you said - you mean the standard 17mm fill hole on the side of the diff ? This sits right on the diff - check it isn't interfering in anyway - I'd drop the box as soon as possible and recheck for obvious wear or loose bits on the clutch parts- then consider opening up the box and see what happening

yeah no worries bus

Yep the drain plug, hmm dunno how it would interfere but i'll check it out, next step is to drain box, if its got plenty of metal in it i'll know whats up.

Will drain it tomorrow when missus moves her car.

Thanks for the input!

[u mad?]

put a long screwdriver against the gb casing with car running

you can hear very clearly using this method,like so

http://s23.postimg.org/c9aks70wr/Diagnosing_Cylinder_head_noises_with_screwdriver.j pg

also drop the mtf using coffee filter asap and see what comes out





obviously gearbox out needs to happen but for now I'd do those..
Thanks clint thats a good idea. yeah im aware im ganna have to drop the box again, ugh fukin hell.

And yep, as i said in previous post, ill drop it tomorrow and post results.

[chez00]

Hey bud I'll reply to your PM soon.

Yeah you just need to rule out the obvious ones like loose fasteners, dust shield grinding against the ring gear.

What happens when your foot is on the clutch while the car is idling - any noise? If the noise goes away you can almost definitely say it's internal or less likely something to do with your pressure plate or thrust bearing. What's an exedy stage 2 - is that one of those god awful 3 puck things with 200%+ clamp load? They eat gears for breakfast. Even when you think you're being gentle they are putting huge shock loading through the mainshaft and usually 2nd gear is the victim.

Re: drain bolt. Any aluminium chips that may have ended up in the box would not destroy gears or anything like that - gears are like 55 rockwell + while aluminium is nowhere near that, so they would just chew it into a paste. That doesn't mean you don't have a shagged gear or something, but I doubt a few chips would have caused it.

If you've got aftermarket drain plugs, some have a really long magnet on one of them while the other is short. I think from memory the long one is for the drain and the short for refill, as the refill is very close to the crown wheel as bennjamin has said. Check you haven't mixed them up if yours are like that.

Before you rip it out, listen carefully for any noise with the clutch pedal depressed and the engine idling. Then very gradually release the clutch and listen for when the noise returns and report back.

[u mad?]

Thanks for the reply, Yes i just tried putting foot on clutch, that rattle you can hear in my video goes away, but, with the clutch still in, if i rev it, it will rattle quite loud, sounds absolutely horrible.

I can actually feel the rattle in the clutch pedal.

Yes i definitely haven't mixed up the drain and fill plugs.

Re the alloy through the box- that is good to know.

Exedy stage 2 is a 3 puk cerimatelic with roughly 40% extra clamp load over oem.

[u mad?]

Wel l i just dropped the oil:

http://i1095.photobucket.com/albums/i477/umad91/gearboxoil3.jpg
http://i1095.photobucket.com/albums/i477/umad91/gearboxoil2.jpg

looks like silver paint.

Well fuk. For some crazy reason im almost glad its the box and not the clutch, at least i didn't fuk up the install. But in saying that there goes 2500 bucks down the drain.

[mocchi]

fuk

thats def look like some destroyed isb

[u mad?]

fuk

thats def look like some destroyed isbwhat, just isb? how is this caused? installation error? too much weight on input shaft trying to wiggle box into clutch spline?

[chez00]

Nah not just isb, my money is on 2nd gear explosion - too much metal in the oil for bearing failure. The rattle is the missing teeth coming into sync, being a constant mesh gearbox. Hopefully there's some recoverable bits in there.

[bennjamin]

Did u let the gearboxs weight sit on the inputshaft as you tried to line it up when installing ? You might of started the end of its life.
As chez said time to open up

btw A blown isb will give terrible noises as the carrier rips apart and little bearings meet each other inside. Drop open clean inspect

[mocchi]

Nah not just isb, my money is on 2nd gear explosion - too much metal in the oil for bearing failure. The rattle is the missing teeth coming into sync, being a constant mesh gearbox. Hopefully there's some recoverable bits in there.

yea true sounds like alexs box too
shieeeeeeettttttttt

[u mad?]

Did u let the gearboxs weight sit on the inputshaft as you tried to line it up when installing ? You might of started the end of its life.
As chez said time to open up

btw A blown isb will give terrible noises as the carrier rips apart and little bearings meet each other inside. Drop open clean inspectI tried not to, but with limited tools to work with i may have done.

[cbauto]

Ask Alex if he will let you borrow his bok....

[u mad?]

lolwut, then he got no bok

[mocchi]

updayte pls

[u mad?]

sold car

[mocchi]

sold car

http://www.ozhonda.com/forum/customavatars/avatar11984_26.gif

[u mad?]

jk, i'll pull it out tomorrow.
my body is ready

[RenzokukenJ]

Fakkkk

Good luck bortato

I pray to allah for your safety

[u mad?]

http://www.ozhonda.com/forum/customavatars/avatar37219_15.gif

Thanks for your prayer



Just realized i need to keep car movable for the weekend, housemates get back from thailand, gotta get to the backyard to take shit to the dump. Will update thread with juicy ruined gearbox pixs on the weekend/early next week.

:thumbdwn:

[chez00]

How'd you go?

[u mad?]

Still waiting for a mate to move stuff outa backyard. Hopefully this week some time, but more then likely weekend now.

[Adrian @ SAS]

Put your old tune back in, less power & box will last longer :p

[u mad?]

Put your old tune back in, less power & box will last longer :p
lol,might be onto something here

[cbauto]

Put your old tune back in, less power & box will last longer :p

Shhhiiieeeeee

[grifty]

You should upgrade to a Polo, the gearboxes on them are tough.

[Super-DA9]

Polo w/DSG swap

Garantee you won't regret

[RenzokukenJ]

10/10 would polo swap again

[u mad?]

i'v since sold the car and bought a polo

never looked back

[RenzokukenJ]

put a long screwdriver against the gb casing with car running

you can hear very clearly using this method,like so

http://s23.postimg.org/c9aks70wr/Diagnosing_Cylinder_head_noises_with_screwdriver.j pg

also drop the mtf using coffee filter asap and see what comes out





obviously gearbox out needs to happen but for now I'd do those..
Did you listen to your car? Did it tell you secret?

"buy polo bro fuk me off ay"

[mocchi]

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[RenzokukenJ]

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http://www.ozhonda.com/forum/customavatars/avatar37219_30.gif

[Super-DA9]

Lmao that last one was gonna be my next avatar lololol