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Discussion Starter #1
I just bought a 1986 Alfa with only 38k miles and am having some issues with the clutch. When I bought it the clutch seemed a little sloppy and intermittantly would grind into 1st and second so I replaced the master and rebuilt the slave cylinders. I also replaced the main clutch rubber hose and blead the system with the slave bleeder at 12 oclock. Now the clutch feels much better, the slave is opening the entire way (11-12mm) but it seems to open only when the clutch is fully depressed (could be normal). My main concern now is that I get a horrible sound when I am releasing the clutch under power (like starting up into 1st from a stop or a hard acceleration from 1st into 2nd). Any ideas what may be causing it? I did use a lot of penetrating oil on the slave to get it loose and maybe got some up into the clutch plate. Im shooting in the dark here. Any ideas would be greatly appreciated.
Thanks
Joe
 

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I don't suppose you have any idea about the condition of the throwout bearing or the shaft it rides on do you? (if either is too raggedy, it'll definitely make some noise, primarily a nasty rattle)

How about the master cylinder activation rod length? (picture in here somewhere)

It has to be quite specific or you'll get really goofy gear action when working the pedal. (not to mention blowing the piston out of the slave cylinder if it's way too long)
 

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Discussion Starter #4
Thanks Tifosi,
I did measure the rod before I installed the master cylinder. I have no idea what the condition of the throwout bearing or rod is. I did call the local "import car specialists" and they laughed when I asked if they worked on Alfa's. It looks like Im on my own here. Im fairly mechanically inclined but never did a clutch and am a little hesitant on pulling the gearbox to work on it. I'll double check the rod length. I was just praying that there might be something easy Im missing.
Thanks again.
joe
 

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Have you checked for the proper level of lubricant in the transmission?

If the bearing in the throw out bearing is failing, it'd likely make noise independant of whether the car is moving or not. If you are stopped and press down on the clutch pedal is there any noise?

When at rest - your foot off the clutch pedal, where does the pedal lie in relation to the brake pedal? The pedal's actuating arm (aka pivot shaft) is a known weak point. Usually, if they fail it breaks off and the pedal then does nothing. But sometimes the weak weld will allow the arm to twist on the shaft a bit but still work - sort of. Then the pedal doesn't come up fully - it rests about equal to or slightly lower (closer to the toe board) than the brake pedal. And, when you then press down on the clutch pedal, you are not getting full actuation of the slave/throw out lever.

Look here for more info: droopy clutch pedal and replacing the pivot shaft. IF you discover this is the problem, check out this link to upgraded pivot arms.
 

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Ive been told that this should be ignored, and it may be correct, but manual says travel distance for slave cylinder lever should be about 12mm. Ive made mine about 14, to help in preventing grinding. east to check, but need someone in car depressing pedal with you uner car with flashlight and metric ruler.
 
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