New clutch and flywheel making grinding noise and smoking

New clutch and flywheel making grinding noise and smoking

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JDR33

Original Poster:

135 posts

101 months

Sunday 24th March
quotequote all
So I've recently installed a new clutch with flywheel on my starlet 4efe, but upgraded to a 4efte setup with a new thrust bearing and slave cylinder. I did my research beforehand for fitment and it would be perfectly fine to continue.

Come to start it up today after dealing with another problem with the fuel pump earth. Fired up which is great, but heard a loud grinding/ chattering noise from the passenger side.

I turned the engine off and inspected the gearbox. There was some smoke emitting from that area. I tried the gears with the engine still off and all seemed okay. Clutch peddle had pressure as I bled the system. Fired it up again and had the same problem but couldn't get it into gear with it running.

Turned it off and inspected the gearbox and again some smoke was coming out.

When I installed the kit I put on the flywheel first, put new bolts on with loctite and cleaned it down with brake cleaner. There was no visible scratches.
I then cleaned the clutch disc and pressure plate and greased the spline and clutch hole where the spline goes into before installing it with the alignment tool.
The clutch disc was installed with the flatter centre part going in to the flywheel. So the other side that sticks out more was in the pressure plate (if that makes sense?)

Clearly the disc wouldn't fit the other way round. I fitted the new thrust bearing and I put the gearbox back on. Filled up the gear oil to the normal level and then bled the system. Went to fire up today and the above happened.

Did I miss something or do something wrong? Anything I can do without taking the bloody box off again? Any help would be most grateful!

JDR33

Original Poster:

135 posts

101 months

Sunday 24th March
quotequote all
On top of the gearbox where the fork is there is a rubber dust cover with a small square hole. That's where the smoke was escaping. It wasn't drastic but it's worrying.