This purpose of this post is that with it's very specific title, it'll pop up when others search clutch noise when the throwout bearing is known to be good. Hopefully it'll prevent pulling the transmission multiple times (as I did) chasing a noise that sounds like a bad throwout bearing when the clutch peddle is pushed to the floor.
Pre '68 Dave is the Master Mechanic that diagnosed the noise in this thread,
Original thread Following Dave's lead, I found factory specs showing clearance for the pp (pressure plate) locating lugs to pp housing of .002 inch to .008 inch. I checked mine this morning , 1 @ .004, then .009 and .010.
So, with a sharp 1/2" chisel and two lb. shop hammer as my only tools I attacked the pressure plate in an attempt to reduce the excessive clearance. I placed the chisel about 1/8"-3/16" from the edge of the lug slot of the pressure plate housing then drove the chisel into the pp housing with two or three measured hammer blows. I did this at each slot (3), drifted metal toward the slot edges, reducing the lug to slot clearance.
Jumped out from under the truck, cranked it up, depressed clutch....NO NOISE!
Disclaimer, who knows how long this band-aid will last. If nothing else, it proved the noise source was worn slots that looked perfectly fine till checked with a feeler gauge.
If anyone else is tempted to try this, hard to believe but it's a pretty delicate process (as in don't wail away as hard as you can with the hammer) and if you tighten the slots up too much, the clutch isn't going to disengage and you'll have to open the slots back up a bit.
Good Luck, Ron
Edited the lug clearance spec from .006 to .008
Ron
