Adam Barnes

I've had this thing since I was 16, so I'm fairly used to all the odd noises it makes. This is not something I've ever head before and certainly not anything healthy. Driveshaft got replaced about 20K miles or so ago. U-joint went bad so I had a local shop replace the entire driveshaft.

You can still hear the normal 'wrrrrrr' from putting the car in neutral. It doesn't seem to change the clunking at all...its just clunking + normal noises.

Here is a video I've posted to youtube:

Phoenix

is it that noise at 3:40? I hear a clacking noise at 5:20ish, which sounds like a rattle of sorts. maybe from interior trim panels.

Adam Barnes

It's some of the same clacking coming from down in the transmission, or from behind the dash...take your pick. That noise was very loud and angry when I got locked out of all the gears. It was strange. I could shift the car fine without it running, but the moment I started it up I was locked out.

I notice input shaft and and main shaft bearings when I'm looking at clutch kits...what would those sound like if they were going out and would they have any impact on me being able to shift?

Phoenix

input shaft and main shaft bearings? I assume you are talking about the throwout and pilot bearings?

Those pretty easy to diagnose, one makes a sound when the clutch is pushed in, the other makes a sound when the clutch is not pushed in.

Transmission lockout you are describing is usually clutch related (or if you actually have electronic shift gates). If the clutch is engaged, it makes it very difficult to put the gear in place. Thanks to your synchros of course.

bleed/drain the clutch fluid, see if that helps, if not, master+slave+ soft line are next. You should also be checking for any clutch fluid leaks when you do this.

Video is not very clear on the noise, I would think thats more of an interior panel noise or perhaps something thats come lose or unhinged and is clacking on stuff near it. But that's a guess at best.

Adam Barnes

They look very similar in photos, so it's probably the same product being sold under a different name. I've got all new hydraulics and lines on the way. Will update after I've bench bled and installed.

Phoenix

they are, just on different ends of the assembly. Although there is probably/possibly minor difference between the two.

Adam Barnes

Master Cylinder :

1984rx7clutchmaster by falcoln0014, on Flickr

Slave Cylinder:

1984rx7clutchslave by falcoln0014, on Flickr

Master cylinder piston is on the left and the piston from a B&A rebuild kit is on the right. The one on the right is the same piston I see with every 84 master kit I can find online. My new B&W cylinder that came in has an identical piston to the rebuild kit (but black metal instead of plastic). Inserting the new piston into my old cylinder did nothing. It would only move fluid around inside the canister on the cylinder.

masteroldleftnewright by falcoln0014, on Flickr

Piston out of my slave cylinder on the left and rebuild on the right. I don't think they're the same size, because fluid simply ran around the rebuild cylinder.

slaveoldleftnewright by falcoln0014, on Flickr

I'm about to get out the micrometer and check each piston to verify diameters...will post that in a few minutes.

Adam Barnes

Old Master Piston: .620 in rings (2), 2.220 in long before back stud.
New Master Piston: .620 in ring, 2.026 in long.

Old Slave Piston: .759 in ring, 1.324 in long
New Slave Piston: .820 in ring (will easily compress down to old size, but that might be the leak problem.), 1.320 in long

I think the largest issue is the double rings on the master piston. Obviously the rebuild kit wouldn't work with it, so it's probably good I got a brand new one to replace it. New hard and stainless lines for the master/slave should be in tomorrow.

Adam Barnes

Clutch kit came in, but I don't see a 'pilot bearing seal' in the kit as I've see in some photos. I'm guessing I need to order a new one before having it put in? That's what I've been reading.

Probably has something to do with my coolant leak...

Bolt snapped. Soaking in WD and will deal with it later.

New thermostat cover. Probably good I found this online as the old one looks pretty sad.

Past time for a coolant flush?

Phoenix

interesting, a clutch kit without a pilot bearing?

I am confused by the differences in the clutch kit. Are they for different years? seems they sent you the wrong ones.