The truck that keeps giving, chattering/clanking in gear

[IslandJ]

Here I am again look for guidance...

quick recap. Engine rebuilt and broke in. New aisin clutch kit installed. Been running pretty great till I hoped in this morning and noticed a chattering coming mainly from the passenger side trans/clutch area. 1st-5th it’s noticeable. In neutral and with clutch in it goes away. The noise frequency increase with rpm only while in gear.
there’s some play in the clutch fork and while I wiggle it around it seems similar to the sounds I hear while driving. I’ll add a link for a video.
My guess is that the clutch fork is bouncing around a bit when it’s in gear, idk. The frequency doesn’t seem to change when I press the clutch in half way or anything.
it only seems to diminish when I put in the clutch peddle and coast.
Is the clutch fork play normal?
any suggestions on where to start?
Oh and I gave the truck some fresh gear oil in the trans and transfer case.

 

[pappy]

You just did a clutch? Check the u-bolts on the driveshaft.

 

[gnob]

What clutch did you use? Flywheel turned?

Run it on jacks or a hoist.

Does it stop when you apply light/med clutch pedal. (not fully disengaged)

Possible the TO clip(s) fell off.

Try pulling the boot out for visual

 

[IslandJ]

You just did a clutch? Check the u-bolts on the driveshaft.

Yeah the clutch has maybe 1500 miles on it. Ill check the U-bolts this evening.
Thanks for chiming in @pappy , I get the most help on this forum.

What clutch did you use? Flywheel turned?

Run it on jacks or a hoist.

Does it stop when you apply light/med clutch pedal. (not fully disengaged)

Possible the TO clip(s) fell off.

Try pulling the boot out for visual

Used an Aisin clutch kit.

Ill try it on jack stands this evening.

The noise slightly changes but doesnt subside like when the clutch is fully pushed in. If I ride the clutch and gas I can feel a vibration that correlates to the noise.

I was leaning towards the Throw Out Bearing clips falling off but I called the company that manufactured my new head and they said that those clips are only for alignment upon instal and they shouldnt have changed anything even if they all of a sudden fell off.
They mentioned that if the wrong bolt was used on the backing plate that it could be the issue. Maybe a bolt started backing out if not torqued properly or the wrong bolt was used in place of the shallow head bolt.

I can hardly see anything through the window... I ordered an endoscope, should be here tomorrow and I'll try the running it on jack stands as well as check the U-bolts.
Not looking forward to dropping the transmission but I plan on swapping in a 4spd into my 1970 Avanti II so I'll have double the reason to buy a transmission lift.

 

[gnob]

What your mechanic said about the clips is nonsense. If they aren't there the TO can spin on the trans snout and damage it.

The backing plate cant rattle with trans attached....

 

[pappy]

The backing plate cant rattle with trans attached....

I think what he was saying was the bolt that holds the backing plate on might have backed out.

 

[IslandJ]

Not that the backing plate is rattling but the bolts that bolt it in place may have been the wrong size. Those bolts have a shallower head and if a standard one was used then it may be rubbing where it shouldn't be. No idea, just relaying info from the company that built the head.

 

[IslandJ]

Got a better angle with my phone and I can see the throw out bearing fork clips but am I missing the wire clip on the fork and would that be causing an issue? Or were those only on later model trucks?

 

[pappy]

Got a better angle with my phone and I can see the throw out bearing fork clips but am I missing the wire clip on the fork and would that be causing an issue? Or were those only on later model trucks?

There are two flavors of throw out bearing. Early, and late. The early has the bearing and hub with the clips. The late is one piece with the spring.

 

[IslandJ]

@pappy in the top picture above, the two rounded areas above and below the bearing, is that the early style clips on the later style fork? Or am I seeing it wrong. Argh, I should just chill out till the endoscope shows up.

And it looks like the the point at where the pivot ball contacts the fork has worn away at that spring. I didn’t notice it until just now. Could that be an issue?

 

[pappy]

@pappy in the top picture above, the two rounded areas above and below the bearing, is that the early style clips on the later style fork? Or am I seeing it wrong. Argh, I should just chill out till the endoscope shows up.

And it looks like the the point at where the pivot ball contacts the fork has worn away at that spring. I didn’t notice it until just now. Could that be an issue?

Fork is the same, only the TO bearing is different. I think the same fork was even used on Tacomas.

To me it looks like you have the early clips. What I don't see is the retention spring on the back of the fork for the pivot ball.

 

[gnob]

Thats what I was thinking. I don't see it in the diagrams but I seem to remember a small wire spring retainer that holds the fork on the ball.

 

[IslandJ]

More picts to come manana.
Had to illustrate what I think has happened.
I cant for the life of me find a clutch fork online that looks like the one I have installed in my truck.
I believe its TOYOTA 31204-35050

 

[pappy]

Had to illustrate what I think has happened.
I cant for the life of me find a clutch fork online that looks like the one I have installed in my truck.
I believe its TOYOTA 31204-35050

I just went through your thread and I didn't see anywhere what you are working on. I get 31204-20070, which superceeds to 31204-20071, $40.20 list, ~$30 discount. This is for pretty much everything 4cyl 1984+. 31204-35050 is a dead number.

 

[IslandJ]

Endoscope picts.
I’ll drop the trans and replace with31204-20070.
Anything else I should check while I’m in there?

 

[pappy]

Endoscope picts.
I’ll drop the trans and replace with31204-20070.
Anything else I should check while I’m in there?

Ya, make sure the pivot ball isn't boogered.

 

[IslandJ]

Ya, make sure the pivot ball isn't boogered.

I'm just gona order a new one while im at it. Looks like it got in a fight

 

[IslandJ]

New clutch fork and pivot ball in. Had the guy the installed my motor do it. Can’t beat his prices when I have steady work going. Truck is with out the rattle now.
He had another 85’ in yard that he is working on and swapped the maf over onto mine and the slight miss was gone so that’s on the list now. He also found a slight exhaust leak at the exhaust manifold flange to the pipe.