Strange sound (with video) after rear main seal repair

Ppd7207

Ppd7207

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Joined
Apr 28, 2019
Messages
52
Location
Phoenix, AZ
So I just finished replacing the rear main seal. Yesterday, there were no unusual noises like this. Today, there is an odd grinding noise when at speed, and the clutch pedal is depressed. It doesn’t make this noise below about 30 MPH. I replaced the throwout bearing, clutch, and fly wheel about 3 weeks ago. Used the Lux Kit. Here is a video of the sound.
 
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Did you torque the main bearing caps after replacing the rear main seal?
 
I did. I loosened the back 3 caps, tightened all 3 to 80 ft pounds and verified the 4th one from the back was also at 80 foot pounds.
 
Start the engine and depress the clutch pedal slowly and make note of how the sound begins. Does the noise change as the pedal travel increases?
 
I have a feeling the throw out bearing is binding on the shaft preventing full movement in or out. The bearing that comes in the luk kit is junk. Its always recommended to use the National bearing when installing a new clutch. I believe this is the link.

https://www.amazon.com/gp/product/B000BZIQ4Q/?tag=wranglerorg-20

Not saying the bearing is junk from the box, just whats a common suggestion. You lubed the shaft I am assuming? Also assuming you used the provided alignment tool?
 
Daryl said:
Start the engine and depress the clutch pedal slowly and make note of how the sound begins. Does the noise change as the pedal travel increases?
Click to expand...
Sorry it took so long, work and all. So we just did this. With the engine running and in neutral, I can’t hear anything when the clutch is pressed in and out slowly.
 
A side question. As I was working on the RMS, any chance that impacted the pilot bearing in any way? As far as I know that is the only connection from the crank shaft and the transmission. I’m just having a hard time believing the throwout bearing worked perfectly Friday when I pulled it into the garage and it was bad on the very first time I drove it after replacing the RMS.
 
The bearing would be set into place on the clutch fork that rotates on a "ball and socket" then is pushed on the other end by the slave cylinder rod. Is it possible you didnt seat that correct?
 
I just pulled the transmission yesterday. When I did the clutch, I replaced the pivot ball as well as the retaining spring. With the transmission removed, I don’t see anything obvious. Release bearing seems fine, pivot ball fine, spring looks to be installed correctly. I haven’t pulled the clutch off yet to check the friction plate, but externally it appears fine to me. I’ll pull it off today and see if there is anything obvious. Sadly I threw out the alignment tool because...when would I need that again. So I have one ordered but it won’t be in far another week.

Here are some pictures. I’ll attach more after removing the clutch.
 
Ppd7207 said:
I just pulled the transmission yesterday. When I did the clutch, I replaced the pivot ball as well as the retaining spring. With the transmission removed, I don’t see anything obvious. Release bearing seems fine, pivot ball fine, spring looks to be installed correctly. I haven’t pulled the clutch off yet to check the friction plate, but externally it appears fine to me. I’ll pull it off today and see if there is anything obvious. Sadly I threw out the alignment tool because...when would I need that again. So I have one ordered but it won’t be in far another week.

Here are some pictures. I’ll attach more after removing the clutch.
Click to expand...
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Nothing is looking odd to me. Here is an amazing video, I understand its an ax5 but the install is the same. Maybe just watch it and put it back together. Did you replace that plastic ball that is used on the fork? I know amazon or quadratec sells them, or both. Its a cheap piece that was recommended to change out while in there. Prolly not your issue but might be worn down causing a little movement., just a thought. I would also put the "national" throw out bearing in there now that you tore it back down.

 
Finally had enough time to get the release bearing replaced. Put in the National bearing. Sound still happens. What would the next thing be?
 
Odd twist, on the advice of a friend, I pulled the rear drive shaft and drove it in 4 high. No sound. Opened up the rear differential, and didn’t see Anything obvious. The RTV is drying so I can’t see if draining and adding new oil did any good.
 
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Custom 4x4 shop says it’s the transmission, his transmission guy says maybe maybe not. A different Jeep mechanic said maybe the transfer case. Going to rebuild the transfer case first and then get a remanufactured transmission of that doesn’t work.
 
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