Spec Stg3 Clutch Issues

the Issues begin and now this has put a complete spanner in the works for the turbo install to go ahead, as some will know about my gt2x build thread......

So............

The clutch was installed on Monday 2nd June. The actual installation of the clutch went on without any issues at all.

Through driving the car, it drives absolutely fine, gears engage fine etc and the clutch also drives fine (all be it a little bit jerky in 1st gear due to it bedding in still)

The issue starts however when the car is sitting idle. If you press the clutch pedal in, the rattling sound as I can only describe it stops. Upon releasing the clutch pedal, the rattling sound then comes back

Upon speaking with the mechanic (this was carried out at Storm Developments who are a specialist VAG tuner and fitter, and always do an A1 job) he commented he was unable to use the cylinder type tool, which aligns the clutch and release bearing, due to the tool being quite badly damaged (this came with the kit), so had to use their own tool which worked fine.

Due to the tool being damaged, and the box the kit was delivered in was quite well packaged, this makes me think that the clutch was slightly damaged due to quite a heavy impact from something during transit/delivery of the kit. Visually it looked fine (although if one of the forks was out of alignment, and it would only have to be every so slightly, this would be very difficult to spot). There are two possible causes of the rattling. A faulty clutch release bearing or one or more of the forks on the clutch is slightly out of alignment

The rattling sound is definitely not a sound due to the clutch bedding in, and speaking with a mate who also has the same clutch, this is a sign of a fault with the clutch as it should not be making this noise. If one of the forks is out of alignment then this would explain the rattling as it is not sitting flush against the release bearing

What I would like to know is where I go from here?

Having already spent considerable money on the clutch and lightened flywheel, considerable time getting this too and from the garage and just over a days cost for labour to install the clutch, I do not want to then have to spend more money on resolving this issue through extra and unnecessary labour

I have spoke to TTS roadsport who have supplied the clutch, and I am going to their workshop next Friday for them to investigate this rattling sound further

anyone had experience of a similar issue like this before at all?

as I dont know how long this issue is going to take to fix....there is now no planned date for the turbo install to go ahead

devonmikeyboy said:

Was it a lightend SMF they fitted ?

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SMF? small mass flywheel

lightened flywheel was fitted as yes, if thats what you mean.....

still it should not be making that sound

AwesomeSarah said:

Hi
The SMF is the single mass flywheel
Yes they do make a bit of noise
Sorry
Sarah

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thanks Sarah, but this is certianly not the usual noise, this is definitely some form of mechanical fault - and it is pointing towards the clutch at the moment

have to see what TTRS say next Fri when they investigate it....

PhilW said:

Sounds like a rattle/grind but is still there slightly when you press the clutch?

Whats the weight difference between the dual mass and single mass lightened fly on an 02m box? bet its loads.

Probably just flywheel chatter/gear lash that you wouldnt normally hear with the standard DMF.

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thanks Phil and Junior

your opinions have made me think it is a little more normal, and laid my mind to rest a bit on this issue but I will get TTS to still check it out just in case

although having heard it, and knowing that ususally a hearing a rattle from the car means there is something wrong, which could clearly not be the case here.......

it drives completely fine though. I will see if the noise dies down over the next couple of hundred miles which it may well do...

EDIT - I think its something like 5-6kg lighter isn't? which is a lot

jaymd said:

Which box have you got 5 or 6 speed?

I was always under the impression the light weight flywheel on the 6 speed 02m box is a lot worse than the 5 speed 02j box when fitting one of these.

The sound does sound normal and suspect that their is nothing wrong.

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it is a 6 speed box

your explanation may sum up why my mate does not have any issues as his is fitted to a 5 speed on his Ibiza

if it is due to the lightened flywheel, then how does the lightened flywheel equate to producing more noise or in this case a rattling noise?

jaymd said:

I'm not exactly sure but i would suspect the DMF does some sort of damping and replacing this causes the rattle.
I suspect the lighter you go on the flywheel the worse it gets.

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good point yes, and that does make sense, less material = less surface area to soak up the vibration

I do approximately 60-70 miles a day, so it should be pretty obvious if it does die down in terms of noise

RobDon said:

Rattling is normal on single-mass flywheel conversions, mine has done it since the day the Helix kit was installed, it's just the shafts rattling around, nothing to worry about. The flywheel is half the thickness of the dual-mass, plus it does not have any dampening like the DM does.

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thanks Rob, your advice is much appreciated

I am not sure if a visit to TTS is still required now, based on what a lot of people have said - oh well I have booked the day off already so might as well just to get another opinion, and if it is fine, then its more miles to bed in the clutch and brakes

AwesomeSarah said:

I always descibe it as a sandwich and a slice of toast
The sanbich has 2 slices of bread
On goes to the engine , one to the gearbox
The rattle from the engine is taken away by the meat in the sandwich
By adding a slice of toast , you are bolting direct from the engine to the gearbox , and you have no meat to take away the noise and vibration from the engine to the gearbox
Blimey , hope you understand that
Yes the weight is alot different too
Sarah

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thats one of the best explanations I have ever heard on a car related issue

its all clear now