Possible issues with new clutch/flywheel/tob install on Subaru

[LudwigVan66]

We finally got it back on the road last night, after it being all over the garage for the last week. We followed the new DIY for clutch replacement and for the most part everything went quite smoothly from start to finish. The flywheel is a "new" Fenco unit from Autozone, and the clutch kit is the OEM style Exedy with new bearings as well.

When I turn the key I'm getting a fairly loud shrieking noise that lasts until the engine fires up. Could it maybe be that the profile on the flywheel teeth may not be mating perfectly with the starter now? It never made this noise before. Also, there is a very slight clicking sound when idling, but that goes away when I depress the clutch pedal. Although that noise seems to be getting quieter now.

What is all starting to come together, the final peices of the puzzle being these noises, along with the wear patterns on the old components.  Here is my idea.................. The snout on the transmission has a soft aluminum sleeve on which the TO bearing slides back and forth.  Said snount gets worn and grooved, causing the TOB to wobble and wear prematurely, which in turn puts uneven pressure on the PP fingers, which also possibly caused the disc to wear unevenly.  I remember reading about this snout/TOB retrofit kit several months, but I thought I remember someone telling me that it wasn't and issue with the earlier cars.

http://subaruwrxparts.com/shop/pc/viewPrd.asp?idproduct=1793&idcategory=0

Man, I sure hate the thought of pulling all of that out again and spending more money too. 

[LudwigVan66]

From subaruwrxparts.com




THE PROBLEM:
These are the most common symptoms associated with a damaged or grooved quill on a transmission.  It is also referred to as the snout, bearing carrier, or case extension.  In most cases it is an integral part of the transmission case & cannot be replaced.  The logical solution is to replace the case or the transmission.  Both options are expensive & time consuming, neither of which solves the problem permanently.

THE CAUSE:
In the operation of the clutch, the release or throw-out bearing slides on the clutch snout or quill, allowing you to engage and dis-engage the clutch mechanism.  Due to various reasons the quill becomes grooved over time.  If the quill were made  of a harder metal than aluminum, this would not be as common.  The most common causes are: improper clutch adjustment, defective clutch assemblies, stop &  go traffic, keeping your foot on the clutch (commonly referred to as riding the  clutch), loss of lubricant, heat, & etc.

THE EFFECT:


The effects of these grooves on the clutch operation are catastrophic.  They cause: premature clutch disc wear,  premature bearing failure (further adding to the problem), sticky &/or jerky  pedal travel, rattling clutch forks, transmission damage, etc.



THE SOLUTION:



The Transmission Sleeve Kit (TSK) solves this problem by utilizing a sleeve, precission machined out of 303 Stainless steel,  which slips over the original quill. This provides a smooth, hard surface  for the oversize bearing to slide on. It is anchored with set screws and is  removable & re-usable. As in the case of the Subaru, it must be removed in  order to allow any transmission repairs.


THE RESULTS:



After installing the Tranmission Sleeve Kit (TSK) you have  eliminated the problem forever! You will notice a smooth, fluid like, feel to  the pedal. Your engagements will be smoother. Your clutch will last longer. This  in turn, will reduce the wear on your transmission.  It will never groove again!


THE KIT:



The kit comes complete with a  303 Stainless steel sleeve, set screws & hex wrench, oversized release  bearing, hi-temp grease packet, notification sticker, & instructions. The  kit comes with a 1 year, unlimited mileage, warranty


Replaces Subaru part #: 30502AA051