MX5 Drivetrain Clatter from Upgrading Clutch

[Bbthree]

In brief, as im utterly frustrated with this problem:

Dipping the clutch in any gear causes a huge clanking rattle through the whole drivetrain.

Things that i have checked/done:

-Open diff has had backlash reset/adjusted. Its also been welded. Was fine before clutch upgrade. Doing this to it has made no effect on the noise
-Its no an exhaust rattle. its a heavy metal clanking that emanates from the gearbox area
-Polybush diff mounts and all suspension mounts and brand new suspension although its clearly not this
-Ujoints are fine
-Ive tried two different gearboxes
-New thrust bearing
-Pilot bearing is fine
-Still have original OEM flywheel. Was perfectly ok before clutch was changed
-Clutch was torqued and installed to spec
-Clutch pedal, slave cylinder etc has been adjusted correctly
-Engine mounts are sound.
-PPF is installed exactly where it should be (66mm although this is a bit of joke to measure to this accuracy)

The only thing I can think of as I've taken every single piece of stty Pants Johnson (thats what i call my car) apart and this is the only thing thats left. Im reluctant to buy a brand new one or lightweight one as they are expensive and i don't hold much faith in it being that.

Ive seen so many posts about this problem and no one knows what it is. Ive also seen daft comments like "they just do that". They don't do it when they come from the factory.

Its also not the fact that its a performance clutch. Before i put that in, i put in a brand new OEM clutch and it made this noise. I upgraded to the high spec one as someone suggested the new OEM one could be a bit crappy. This has made no difference

Really really struggling on this now

https://www.youtube.com/watch?v=L7x5pW4VFj4

thats the noise?

[izzybella]

Hi Sorry I dont mean to belittle you as you sound like you understand the car Can I ask has the clutch plate been put in the correct way if the c/plate has different size spline bosses each side it maybe that when the clutch is compressed it is bottoming out on the crankshaft pushing it forward and reducing the clearance on the c/shaft wearing out the thrust washers and damaging c/case. Or maybe the withdrawal sleeve is not what it should be or cracked

Hope you get it sorted

Alan

Edited by izzybella on Thursday 16th April 22:37

[xyyman]

Had a similar issue, albeit not on an MX5, and turned out the clutch had not been centered correctly when the new one was installed. Doesn't have to be far out to cause vibration.

[Bbthree]

You can’t get the clutch out of line. It’s got centring dowels on the flywheel and the spigot bearing holds the input shaft centred.
I’ve also put in two different clutches and it makes no difference

[izzybella]

Just to be absolutely certain I would ask a friend to press the clutch whilst you watch the crank shaft pulley for forward movement to disprove for you own piece of mind and speak to you clutch assy to see if there is a variation of plates.