Hi all,

Wondering if any of you can help.

The car is a Mk III face lift, 6N2, 1.4, 5 speed. 123,000 miles. Clutch replaced around 15,000 miles over 2 years ago but suspect release bearing not replaced - now out of warranty. Recently had gearbox oil level checked at Halfords Auto and they said fine but noted noisy release bearing which "could fail at any time". Clutch always been pretty heavy except pre 30 thousand miles - new clutch made only slight difference which didn't last. Pedal box was done at a similar time to new clutch.

So I have at least two noises:

As I press the clutch down whilst driving (can't hear while stationary) I hear a continuous change in tone of what I would call a grinding/scuffing noise. Kind of like on a bicycle with grit and water on the rims when you brake gently. Most people wouldn't hear it was there but when you know what to listen for you can hear it. I think this is the release bearing - am I right? Can the release bearing make any other noise whilst you are in gear and driving or is it only when you press the clutch pedal?

The other noise seems to be the gearbox - shall we say whining on drive and engine braking. If I put the car in neutral and coast while I'm rolling along at speed - this noise goes away. Would this be the gearbox gears only (anything else?) or could this be the release bearing too? Halfords said nothing about gearbox noise but they probably only took it round the block.

Selection of gears is not bad apart from the odd grind for reverse. Should the release bearing have been routinely replaced at the same time as the clutch? Is it worth checking the gearbox oil level myself - maybe the garage didn't let it settle before topping up? It's always had a bit of oil seepage around the seal on the selector shaft at the bottom of the gearbox but not enough to leave anything on the pavement.

Many thanks for all your help.

Simon

I would start by checking that the clutch cable is correctly adjusted - If you grab hold of the lever where the clutch cable attaches to (gearbox end) there should be about 6 mm 'free' movement there

(free movement = the lever moves without any pressure on it)

Do NOT increase or (especially) decrease this 6 mm free movement.

If there is already too much free movement, that might account for the difficulty in engaging reverse, but if the adjustment is OK, you can get round that problem when you need to engage reverse by: Pressing down the clutch - Engaging a forwards gear - KEEP THE PEDAL DOWN - and engage reverse.

With the free play correctly set, the clutch release bearing should only come into operation when you actually press the pedal, so noises at other times, should not be from the release bearing.

It is good practice to change the release bearing with the rest of the clutch - most garages will do so.

The noise that you get whilst driving and on the over run, could be due to gearbox bearings, rather than the actual gears - I would recommend that you change the gear box oil and see if there is any improvement.

If the release bearing is noisy, you should be able to hear it regardless of being on the move/stationary.

The 'heavy' clutch pedal MAY be due to the clutch cable needing replacing.

Regards

(edit due to typo)

Edited 22 September, 201411 yr by caretakerplus

Thanks caretakerplus for a helpful and informative reply. I'll get round to having a look at what you say in the next few days. I'll check the free play at the gearbox end - currently at the pedal end there is about 15 - 20 mm of play. I left it like that cos other drivers of the car tend to ride the clutch.

If the release bearing is noisy, you should be able to hear it regardless of being on the move/stationary.

That's the only thing that doesn't seem to add up - I can't hear anything if I press the clutch whilst stationary and with the engine just ticking over. I don't think I do if I up the revs either though will check again.

On replacing the clutch cable: is it serviceable - can I get grease between the inner and outer if I remove it or is it like modern bicycle cables with a plastic lined outer that shouldn't need lubricating but needs replacing once worn?

Now this is a bit of a long shot, and I am not even sure that it can even happen. However, you may care to check it.

I'm just wondering if it is possible for the BRAKE pedal to move when you press the clutch? If it is, there is a possibility that the noise that you are hearing is coming from the brakes (which of course, you wouldn't hear when stationary)

You MAY be able to check this by asking an assistant to watch for the stop lights coming on when you press the clutch.

I know this sounds a bit crazy but at least it should be easy enough to check out.

The only way to check the clutch cable, is to disconnect both ends and check that it is free to slide.

There is no provision for greasing it, but you may be able to get some rubber/plastic tubing over the end and squirt some (preferably) silicone oil through it.

Regards

Thanks for your advice - I will check everything you say. Before that I'll update you on what I've found so far.

At the gearbox end there is approx 6 to 8 mm of slack in the spring for the pedal to take up before the lever on the box starts to be pulled.

The clutch pedal noise IS just audible when stationary and gets ever so slightly louder when you hold the revs up near 2000 or 3000 rpm. However the same noise becomes much louder when the car is driving in gear or rolling along in neutral. The brake pedal does move ever so slightly when you use the clutch probably as the pedal box flexes very slightly - however I'm almost 100% that this isn't causing the brakes to engage. I will confirm this.

Last time I had both ends of the clutch cable free it seemed pretty free to slide but it's something I can check again.

The second noise I talked about - I'll have to look at changing the gearbox oil. I've got the stuff in and the hex key and know where the drain and fill points are but have not done the job. Will have to get a tool to help me fill the box.