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My clutch fork theory was wrong...didn't end up replacing the metal spring with the plastic socket b/c I cannot fully remove the clutch fork with the trans in the car. The amount of pivot ball spacing I have prevents the fork from coming out. Also, when attempting to remove it I realized that there would have to be a large vibration to overcome the spring pressure from the slave cyl in order to let the clutch fork rattle and the vibration that I am experiencing doesn't seem large enough to do that. So, bottom line, I still don't know what is causing the rattle.
I borrowed a GoPro to watch what was happening at the axle when the vibration happens. Overall, nothing too exciting, but I was surprised the pinion moves as much as it does. I was not driving hard at all for the video.
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Yea, I hear ya...frustrating not knowing the source of the issues.Mine makes a similar sound at 2700 to 2500 rpm. I'm living with it for now. I'm on my second trans tailshaft (once the bushing spins in the tailshaft it's almost impossible to keep it from happening again), third output bushing, and second driveline balance job. I'm sick of chasing the noises and vibes in my setup. Frustrating.
Thanks for the info.What was your procedure for setting pinion angle?
What is the rear u-joint angle? Should not be more than 3.5 degrees. https://www.hurst-drivelines.com/files/Universal_Joint_Alignment_Proc_111606.pdf
Are the front and rear u-joints in phase? http://www.behlingracing.com/behling-racing-technical-information/u-joint-installation/
Usually you will want it 1 degree down from parallel compared the transmission's thrust centerline. Conversely, you could switch to a two-piece setup.
Hope this helps
After checking the driveshaft angles, I needed to make a slight adjustment to the torque rods to bring the pinion 1* nose down which also brought the u-joint angle at the transmission slightly below 3.5*. This change may have made a very slight reduction in the rattle, it is hard to say, but the rattle is still there.
Another question...how much "free play" should the driveshaft/pinion have when the trans is in neutral and the parking brake is on?
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