OK so bolt it/tighten and then cut? I don't remember if there is enough clearance to cut with it bolted it, but I'll get back there shortly and see what I can do.
Thanks a lot!

 

You should be able to get to the end where the zip tie hooks together. it will be right againt the bellhousing. I can see it in your pic. Just cut that after installing it and the slave will release fully.

 

OK. This better do the trick. I have to drive a few miles over there and back.
I'll post when I get back. Thanks again!

 

no prob, I am gonna get to bed. But I will check in the morning and see what happened. Good luck and I think this is the problem you are having.

 

Well that didn't do the trick.

I can definetely tell my clutch wasn't engaging properly before though, because I can actually hear it now and it goes into gears much smoother. (just like it should. it was a little hard before)

The noise is still there. There are definetely no exhaust leaks. The engine was running perfect before and the only way I could have screwed up anything is if I pounded the pilot bearing too hard, but I used a socket and didn't hit it that hard. So I don't think it's the engine.

It goes into all gears. I shifted it into first and second and the wheels are turning just like they should. This tells me the clutch is installed correctly. Same goes for the fork since the clutch engages well now.

One other thought though... is there any way it could be the starter? Since the noise seems to be coming from that way. I might pull it out tomorrow and if I don't find anything there, I'll pull the tranny out.
Thanks.

 

Let me know if you need a hand. I am free tonight and dont mind comin out to help. I know pulling the trans all by yourself is no fun. Let me know. That is if its not the starter but I can still come out and try to help ya figure it out.

 

Wow, that's a very generous offer. Thanks!

I usually work on the car late at night. Something like 10 to 3 am and I don't know if I want to subject you to the tight clearances of my garage. It's a PITA to work. I've pulled and installed the automatic about 3 times all by myself and also installed this M6 myself so I'm OK, but if you still want to stop by, sure! We can trade your help for some dyno tuning if you want. I have a couple dyno days soon.

 

Ion did you see if the arm of the clutch fork is hitting the preasure plate? Has the noise gotten louder or stayed the same? Did you match balance the flywheel?

Chris

 

Well its up to you, I couldnt stay that late as I am gonna be leaving for the weekend the next morning early. Like 5 am early. Just wondering if you pulled the starter out yet and seen if it is rubbing on anything?

 

Chris, it doesn't look like there's a problem in the fork/pressure plate area.

I pulled the starter and I could not find any visible damage on it.

However, it seems like some teeth on the flywheel are grinded a bit on the engine/starter side. (although I can't be sure if it's from my car or the car it was on before)

You can see what I'm talking about here.

This is not on all teeth, only on areas like the one in the picture, which leads me to beleive the flywheel may not be flat. If that is the case, what is it grinding on? The only possibility would be the starter, wouldn't it?

Here is a video of the flywheel turning, although it's not a very good one. (7 megs)

Either way, it definetely sounds like the noise is coming from the starter area. If it's the pilot bearing or clutch/flywheel, I would think it would resonate just as loud on both sides, but it seems to be louder on the starter side, even watching the video.

Let me know what you think.

 

did you pull off the starter to see what the gear on it looks like???

 

Yes, the gear looked fine. I'll check it again tomorrow.

 

Well, I dropped the tranny today and found the problem.

It looks like the aluminum flywheel I have is out of round. About 1/3 to 1/2 teeth on the flywheel are hitting (barely) the ring on the starter shaft. (the marks on the teeth were about 1/8 long)

I could see marks on some of the teeth, but not all.

So.... is it normal for the flywheel to be like that and should I just shim the starter or should I get my steel flywheel resurfaced and use that instead?

 

Today was just a tranny dropping, problem finding day for the both of us. I still have a stock flywheel, so I cant answer your question

 

Damn it, I would've put mine in back today too if any machine shops were open to resurface my stock flywheel.
What's wrong with yours?