New LUK clutch, new noise, looking for advice
So I bought a LUK clutch kit (07-155) for my 2000 as my pilot bearing was shot and I thought my throwout bearing was too. Everything in the bellhousing got replaced for good measure and the input shaft had no play that I could detect at all. I was VERY meticulous in replacing the clutch and I LOVE the way it shifts now, but the noise is going to give me ulcers.
So I knew beforehand that some people have gear rollover and that sometimes it gets worse when replacing the clutch and flywheel with an aftermarket type, but some others have it go away or at least diminish. Seems like you just have to try and see which happens, I had mixed results. With the stock clutch at 112K I had rollover while in gear when I was under power at 1000 rpm or less, basically when I was lugging it in a parking lot or something. That's gone now! It's been replaced by rollover when in 1st, 2nd or 3rd and decelerating between 1500 and down. So in parking lots, slowing down for traffic lights or a u-turn, traffic on the freeway, etc. I also have more general noise and vibration from the engine at all speeds and RPMs now too. It's WAYYYYY more annoying and I know people say it's not a big deal but it's the bearings rattling around inside my transmission!!! How does that not make people crazy?
I have spent a lot of hours, too many hours, looking for solutions to this before posting here. I have read about changing the fluids to different brands, mixes of synthetic and conventional fluids, adding motor oil, gear oil or additives with moly and graphite. My tranny is currently filled, and it's full, with Mobil 1 synthetic with about 5K miles on it so I would prefer not to dump $60 worth of fluid just to try something else out. I have searched for advice on what brand of clutch is known to be really quiet but they all seem to have problems or the people who have quiet clutches are staying quiet too. Even the factory clutches which are have horrible pedal feel have mixed reviews on gear rollover. Mine had it, but it wasn't bad before.
I have considered taking the clutch and flywheel back out and having them balanced at a machine shop even though they are supposed to be a balanced set, but I can't seem to find ANYONE who has done this with a powerstroke. It might be a complete waste of time and solve nothing. What is the CAUSE of the rollover noise and what would make it so different between the two clutch setups? They are both solid flywheels with single discs, why so different now?
So who know's a lot about clutches? Does anyone know of a particular brand that is supposed to not have rollover problems? Does anyone know of a way to eliminate or reduce the rollover noise with a LUK type clutch? Would having the flywheel, disc and pressureplate balanced by a machine shop help? Does anyone know if it is the different design of the pressureplate, the clutch disc or the different weight of the flywheel that is causing this? Do I need to look at a clutch that is based on the stock design, maybe even using my stock flywheel, to get the rollover under control?
I really like this truck. I like the manual transmission, I like the manual transfer case, I like the bench seats. I installed an Donaldson AIS air filter and I have a NUC bypass oil and Diesel site coolant bypass filter to install because I want it to last. I am going to rebuild the entire front end soon too. I want to drive it a long long time, but I have got to figure out this rollover noise. It's gonna make me crazy...