Bails · Feb 17, 2017

Hi all,

I had the clutch replaced about 6 months ago in my 200tdi 87' 90. Mid house move, the slave cylinder punched a hole through the clutch release fork and so I had to get the local trusted mechanic to do it for me as all my stuff was packed.

Right from when it was newly replaced, the clutch made a loud rubbing/squealing noise when I let the clutch in in first gear (to pull away). I was concerned and took it back, but as I took it back, it stopped. Anyway, now it is back with a vengeance, squealing as the clutch comes under initial load. It also now squeals for a second or so after I have been cruising with the clutch out and also sometimes squeals when I change down into 4th. It only squeals if I let the clutch in normally, it doesn't if I let it in quickly. Its probably also worth noting that I have fitted a roamerdrive overdrive within the last month (ready for a 3 week solo holiday around Europe) and have been enjoying the ability to do 70mph

. I'm thinking this may have revived an underlying problem.

I now get funny looks at roundabouts and traffic lights when pulling away. Its beginning to get annoying on my 60 mile return journey to work everyday. Any ideas or advice would be much appreciated.

Tony e · Feb 17, 2017

Sounds like it may be a dodgy thrust bearing

Gazbo · Feb 17, 2017

Bails said:
Hi all,

I had the clutch replaced about 6 months ago in my 200tdi 87' 90. Mid house move, the slave cylinder punched a hole through the clutch release fork and so I had to get the local trusted mechanic to do it for me as all my stuff was packed.

Right from when it was newly replaced, the clutch made a loud rubbing/squealing noise when I let the clutch in in first gear (to pull away). I was concerned and took it back, but as I took it back, it stopped. Anyway, now it is back with a vengeance, squealing as the clutch comes under initial load. It also now squeals for a second or so after I have been cruising with the clutch out and also sometimes squeals when I change down into 4th. It only squeals if I let the clutch in normally, it doesn't if I let it in quickly. Its probably also worth noting that I have fitted a roamerdrive overdrive within the last month (ready for a 3 week solo holiday around Europe) and have been enjoying the ability to do 70mph . I'm thinking this may have revived an underlying problem.

I now get funny looks at roundabouts and traffic lights when pulling away. Its beginning to get annoying on my 60 mile return journey to work everyday. Any ideas or advice would be much appreciated.

I know the type of squeal you mean, it is a vastly different noise to a failing release bearing, a friend of mine has a Suzuki 4x4 that is making the same noise but it is still running an original clutch that has 170,000klm on it, the good news is that the squeal started at about 100,000klm, so it seems that it may last a bit.
As to what causes the squeal, it could be a badly glazed flywheel surface but I believe that it could be caused by a problem with the diaphragm spring in the clutch warping which gives a sort of uneven pressure on the driven plate on takeup, you say your clutch was new but was the pressure plate as well as the driven, (friction), plate replaced, if your man only replaced the driven plate then the old pressure plate may have not liked it's new tour of duty.
I have seen the cheaper brand clutch kits even from new go that way from the start.

lynall · Feb 17, 2017

As its a three week holiday abroad I would go for new quality clutch for piece of mind, with new slave and master cylinders and release arm, may seem expensive but a failure will be a lot more expensive.

Bails · Feb 17, 2017

The pressure plate was replaced with the clutch, well, that is to say I made a wall clock out of the one he removed...I remember seeing the old spigot bush and it was knackered, really chewed up. The replacement clutch is an AP driveline unit, slave and master cylinders were replaced at the same time, as was the release fork. He gave me the parts he removed as he knows I re-purpose things where I can. I am seriously considering replacing the lot again, but I will have to plan it in as its my only vehicle and I do around 60 miles a day during the week.

freelance · Feb 17, 2017

What condition was flywheel surface? Very glazed I would guess

Bails · Feb 23, 2017

I don't know about the flywheel, I had taken the train into work while the clutch was replaced. However, the squealing has now stopped again of its own accord. This makes me think it might have been a slightly contaminated friction plate or something.

guineafowl21 · Feb 23, 2017

Bails said:
I don't know about the flywheel, I had taken the train into work while the clutch was replaced. However, the squealing has now stopped again of its own accord. This makes me think it might have been a slightly contaminated friction plate or something.

Maybe your man put a bit too much grease on the input shaft and release bearing linkage, and it flung onto the friction surfaces?

Gazbo · Feb 24, 2017

guineafowl21 said:
Maybe your man put a bit too much grease on the input shaft and release bearing linkage, and it flung onto the friction surfaces?

That would only make the clutch "judder", from my experience.

Shanec · Feb 27, 2017

I don't believe this is your problem but I recently learned that squeeks can be caused by failing bearings under laod. Rear UJ had one of the 4 cups completely empty. The bearings has turned to dust. Started as a squeak under load and became a violent shudder through the vehicle.

Bails · Feb 27, 2017

Thanks for your input chaps. It isn't solved yet, but its gone quiet again and more immediate problems in the transfer box have arisen!

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