Clutch Rattle

[BigBlueVan]

Hi All,

I have been trying to get my clutch to release on my conversion, ej20 engine, RJES bellhousing and release bearing, VW clutch disc.

Initially the problems were from the clutch bracket bending and not allowing the clutch release arm to travel enough, I have checked the arm position on the teeth (petrol VW arm) initially on the centre 4 grooves as per RJES instructions, however this would not release the clutch at all.(Visually checked through inspection cover under flywheel)
Moved the arm clockwise to move it closer to the clutch slave cylinder.
Now it releases however if I turn the gearbox to confirm it has released I am met with a loud rattling noise which comes and goes as I turn.

When turning the gearbox output stubs by hand.
#gearbox in neutral - no rattle at all as clutch is not involved
#gearbox in gear - cannot turn as clutch is engaged with engine which is ok.
#gearbox in gear and clutch depressed - clutch releases, gearbox is free to turn but rattles.

Turning then engine crank with a large ratchet.
Same symptoms as above, rattle present when in gear and clutch is depressed.

Any ideas what I could have missed?
I'm A long way from starting the engine so plenty of time to resolve.

Cheers,
Chris.

[BigBlueVan]

Also worth mentioning I have 2 slave cylinder pushrods, these are the original and a new replacement. Slightly different lengths, neither allows for full disengagement.
The slave master cylinder has been checked, the pushrod and nut allow for a small amount of slack before pushing on the cylinder, I tried adjusting this but this only made the master bottom out early thus further limiting the travel.

Photos of 2 pushrods for slave and the support bracket I made which eliminates all flex.

.

Maybe it's normal for the disc to rattle a little and when the engine is turning it will stop due to centrifugal forces. I managed to poke the side of the clutch disc through the inspection cover and it does appear to be free of the flywheel,, with everything being new is the noise just due to everything being fresh and maximum thickness. Head scratching for sure..

[slowcoach]

I'd like to help,but I've never changed a clutch , only the slave cylinder and lines. I have the rjes bell housing, so can take any exterior pics you want. But I'd be asking Richard first

You'll like the drive once you've got it moving though,it's awesome

Sent from my Pixel 4 using Tapatalk

[silverbullet]

Don't mix the cylinders and pushrods, the aftermarket stuff is ok but its all subtly different so keep them as sets.