RaceProfessor

Good morning, I've been searching and was unable to find a resolve so I'm praying you guys can help me.

I just replaced my clutch in my 2009 FA5 with an Exedy Stage 1 08806 with a matching HF02 chromoly flywheel.

Ever since the clutch was installed, at 50+mph, there is a pronounce metallic grinding/rattling noise coming from the trans/clutch area.

It only occurs while coasting, if the clutch or throttle is applied it completely dissapates. I've read everything from throw out bearing, pilot bearing to input shaft bearing being the culprit and I'm on the brink of going insane, the noise is unbearable.

The noise wasn't present prior to the clutch install, I replaced it merely because it was starting to show symptoms of slippage. The technician that performed the work hasn't a clue so I'm looking to the expertise of the members.

The rattling/grinding noise ONLY presents itself while coasting and completely silence itself the moment you press the clutch or thottle. Thank you for any much needed help gentlemen.

slowcivic2k

Drive/Coast noise is caused by gear wear and the meshing pattern. Since the transmission was not disassembled I would doubt gear noise is the source of your complaint.

The dowel pins on the transmission are vital, if there are not installed, crank bearing failure or input bear failure will result. Both will normally present with a failed pilot bearing.

Provided the dowels are intact, and the correct fluid was added to the transmission, you problem lies in the clutch assembly being out of round (runout). This noise can be caused by too little pre-load on the mainshaft which can create noise due to deflection in the assembly.

It would also be wise to note the condition of the engine mounts and any other components related to them. By your description you may have a runout problem in the bell housing.

RaceProfessor

Thank you very much for the detailed description, your input is much appreciated.

RaceProfessor

Slowcivic2k, can the incorrect trans fluid cause such a problem? The technician mentioned he had to put over three quarts of fluid but the oem specs are only 1.7 quarts. I'm using Redline 70w80 MTL.

slowcivic2k

Using an oil that is too thick or thin will cause problems. Too thin an oil will not provide the correct film thickness to prevent gear noise. Too thick will create splattering inside the case which can have the same effect as a low oil level. In addition to this, the oil holes in the shafts may have little to no lubrication because the clearances are too tight for a thicker oil to flow. Use the factory oil or a similar weight performance oil to prevent premature wear. Overfilling can be just as bad as an under-filled unit.

Given the clutch is all you changed, I have my money on something being incorrectly installed, wrong part, or a part out of round.