NA Drivetrain rattle in 1st gear on hard launch.

[Kozy]

Got a nasty rattle coming from the drivetrain in my 1.8 NA any time I give it a moderately hard launch in 1st. It's had a bit of work done recently and I'm not sure which bit has caused it.

New IL motorsport engine mounts.
New Exedy stage 1 clutch
Replaced gearbox
The Type 2 Torsen had a new rear half casing fitted after one of the arms snapped off.

Exhaust was also removed from the down pipe backwards to facilitate all this work.

This noise is a pretty loud rattle, only noticeable when slipping the clutch from about 4000rpm onwards. Seems to be linked to suspension deflection as it doesn't do it in the wet and won't do it in 2nd or higher.

Only using 185/60/14 Vredestein road tyres so not super amounts of grip.

Any ideas? PPF was 10mm out of alignment, but fixing that hasn't got rid of the noise.

[BIG DUNC]

I go for exhaust hitting something.

[feef]

Exhaust heat shield?

[Kozy]

Found it today. When the clutch was changed the PPF was not aligned, upon inspection it was 10mm out from where it should have been. This, combined with loose studs that go through the PPF and diff has caused part of the diff casing to crack, meaning the whole thing is flexing under load causing the coupling on the prop shaft to rub on the PPF. It's caused a nasty gouge in the metal but thankfully the part that has cracked looks like it unbolts and should be easy to replace.

I've also got about 180 degrees of lash in the diff and loose baffles in the exhaust, but that's not a major issue for now.

Edited by Kozy on Friday 4th July 09:06