tinny rattle when braking and/or using clutch pedal

[gunk]

Yay I can post!

I have a 1985 Corona CSi 2.4L with the W57 transmission. Often but not all the time, when I brake there is a loud tinny sounding rattle which sounds like it might be coming from the front of the car somewhere but it's hard to tell. Tonight I went for a long drive just to try and find a pattern to times when it rattles and discovered that it happens far more often when I press the clutch pedal and usually disappears when I release the clutch pedal, unless I'm braking as well.

It's really loud, especially from outside the car and it's been driving me nuts for months. I would really appreciate it if anybody can point me in the right direction.

[grotty100]

Spigot Bearing?

[Kedderz]

thrust bearing im willing to bet!

[gunk]

I hope not, clutch and thrust bearing were only replaced about six months ago. It also happens sometimes under heavy braking, even when the clutch pedal is not being used.

[Talasas]

I was going to say check the pedal box but if you can hear it outside the car maybe not.

So it's a consistent rattle and not a metallic clunk when you push the pedal down?

Does it happen when the car is stationary?

EDIT: I'll also add, check the exhaust to makre sure it's on all the hangers and not free to move around.

[samdowning]

does it happen more if the car is cold? also does the rattle change frequency when you're operating the clutch? if not it's probably not the thrust bearing. my thrust bearing started to go and and it would make a sound like you mentioned but it was worse when the car was cold, i replaced the thrust bearing and the noise was gone, maybe the mechanic decided not to put the thrust bearing in for some reason when he changed the clutch.

[gunk]

I took it to an brake and clutch place today and they took it for a drive. They said it's either an odd disc wear indicator, they have seen a similar one before, or it's a screwed brake rotor. I've booked it in for this saturday morning so they can find out for sure.

["Z" UTE]

gunk, there is a tin cup on the rear of the gearbox extension. There is another tin cup on the tailshaft, a kind of shroud to keep crap off the tailshaft/gearbox output shaft junction.

When you apply the brakes, or engage/disengage the clutcth, through different loads you change the position of the gearbox slightly in relationship to the tailshaft. The 2 tin shrouds are coming in contact with each other. This is probably because the guys who did your clutch bent one or both of these cups. Check them both for roundness, and adjust as required.

cheers Chuck.

[grotty100]

gunk, there is a tin cup on the rear of the gearbox extension. There is another tin cup on the tailshaft, a kind of shroud to keep crap off the tailshaft/gearbox output shaft junction.

When you apply the brakes, or engage/disengage the clutcth, through different loads you change the position of the gearbox slightly in relationship to the tailshaft. The 2 tin shrouds are coming in contact with each other. This is probably because the guys who did your clutch bent one or both of these cups. Check them both for roundness, and adjust as required.

cheers Chuck.

Just adding to this: Also check your engine mounts and gearbox mount?

Grotty.

[gunk]

You were spot on Chuck!

Big dent in one of those tin cups, fixed and rattle is gone. Now if I can just get the stupid nut off the crankshaft I can change my timing chain and drive it again. Driving the corolla instead right now and it's so so slow and a real bastard to drive in the city.

["Z" UTE]

gunk, glad we could help you out. I have the "T" shirt for that one!

cheers Chuck.

[ddeane]

Gunk

Do a search on removing harmonic balancer/ front pully. There are lots of suggestions on how to remove the nut.

But if the rattle gun does not work I have found that the socket on the end of a breaker bar so it is jammed against the garage floor and then turn the motor over on the starter motor works great.

Please MAKE SURE that you have the breaker bar on the correct side so it does not spin and that you make sure that the engine cannot start by removing plug leads ot disconnecting the ignitor.

Cheers Craig