garrett376

And for a little more detailed sound from underneath the car... be warned, it sounds pretty bad!

Anyone have an idea what it is???? I guess I'll find out!

5.2MB file: http://homepage.mac.com/guessendo/bad2.MPG

hawk911

all I got's to say is yuck!!! sounds like a kids popcorn popper push-around toy gone mad.

KirkF

DANGIT!

You gotta drop that motor garrett. I know you don't want to but that sounds horriffic. I was waiting for the shatterring sound as something came smashing through the side of your bellhousing.

I can think of alot of things that could be causing it. Throwout bearing. Clutch guide tube loose, dmf failure.

I was going to ask you to post another clip with the clutch pedal in and then out, but I don't think it matters. You are pulling that setup regardless.

Excess vibration is usually the first step in diagnosing a DMF failure by the way.

Kirk

garrett376

I am hoping it is the flywheel - especially since I have a spare... but what a pisser! Has anyone every had a DMF failure... is this what it sounds like?

Tomorrow I am going to try to do the whole job in a day... I am too tired to try to start it tonight - I spent about 8 hours total doing it over the past three days...

Hambisa

Hi Garrett;
My commiserations, that sounds like the DMF to me, too. I had my clutch done this week at my specialist in La Mesa. They called me in to show me that my DMF was on the way out -- you could move the center back and forth by hand. It had been clattering when shutting the engine off, and now with the new one in, I have noticed that the car idles more quietly, too.
If you would like a helper tomorrow with the R&R, send me a PM or e-mail -- I'd love to give a hand and get involved with a job like that!

JasonAndreas

Garrett,
Do you have a stethoscope at home?

garrett376

Hey Jason - no, but I used a long socket extension against my ear to make sure I could tell where it was coming from. At first I thought it was an engine problem... which scared the crud out of me since I changed the aluminum gasket on the right side chain tensioner cover and thought something went awry.

JasonAndreas

When you install a hydraulic chain tensioner backwards after replacing the right side aluminum gasket the engine sounds more like a sewing machine. All I can add is that you will be amazed how quickly you can drop an engine the second time around with everything still fresh in your memory, I know I was.

Here is Porsche's pre-LUK procedure for determining clutch and flywheel damage.

garrett376

Thanks Jason... it truly sounds like the starter gear is loose... that is the type of sound it's like... I'll find out tomorrow

mark lintott

Clutch release (throwout) bearing knackered I reckon. Relatively cheap to fix but you still have to drop the engine etc.......................

Chris M.

Oh that's hard to listen to. Sorry Garrett. I wish I could say my engine and tranny would be out in 5 hours!!

c

garrett376

This picture says it all:

garrett376

Here's what happened: The dealer sent the the wrong flywheel bolts, and I didn't check them to make sure they were right. A couple weeks ago, I measured my old flywheel bolts because the dealer didn't know which ones to give me. So I called them back and told them I need the shorter bolts; so they supposedly ordered them, they arrived a week ago, and I did not check them when they arrived!!!! I just installed them right out of the box yesterday. Unfortunately, with a flywheel lock in place to torque everything down, I could not tell that the flywheel was not tight against the crankshaft. The incorrect bolt, the long one, was still torqued to specifications because it bottomed out inside the crankshaft . You can see from that image above that the bolt started to strip/deform from being torqued into the end of the crank. Thank goodness I did not damage the crankshaft.

Anyhow, upon disassembly after spending 3.5 hours to remove the engine and tranny (much faster than yesterday!!!), when I separated the tranny from the engine, I could take my hand and wiggle the flywheel - ouch!!! Not good! That's when I realized that Sunset must have shipped me the wrong flywheel bolts. Dang it! I was able to remove all the bolts, and install the proper length bolts this time. Uggh, what a pain, literally. I am so sore tonight, I feel like I've been beat up. But now the clutch works like butter, and sounds just fine! Thanks for the emotional help, guys!

garrett376

Hey Ian, thanks for offering to come help... I didn't notice that in your post until now. I don't think there would have been enough room under there for two of us, though!!! I hope I don't need to drop any engines for a long while. At least until my knuckles, elbows, knees, head, etc., heal up!

Hambisa

I'm glad it wasn't a catastrophe -- too bad that it still cost you to an additional R&R, though. You must have set a record time for a solo engine-out, Garrett! Anyway, the offer still stands if I can lend a hand sometime and save you some skinned knuckles and/or cursing.