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Old 04-24-2010, 05:41 AM   #151
Snowphun
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Replace with stock clutch and flywheel seems to be the best answer at this point.
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Old 04-26-2010, 12:42 PM   #152
jalweber
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I had a similar problem, turned out the diff inside the tranny had grenaded and made a pretty good mess of all the shafts and gears inside.

Ended up with a full tranny rebuild courtesy of Subaru.
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Old 04-29-2010, 07:43 PM   #153
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I just started getting this same grinding noise after a new clutch install last week. On Tuesday of this week, I started noticing a wierd grinding noise under the car that happens when I lift off the throttle around 2-3,000 RPM. It doesn't seem to happen (or not noticeable) in the morning, but I can definitely hear it throughout the day when I'm driving (I guess after the car has warmed up). It seems to be something with the clutch, because when shift out of gear, the noise goes away. Also, there isn't any grinding when I'm on the throttle.

I guess I assumed wrong when I purchased the Exedy OE clutch kit that this was the same as the Subaru OEM clutch kit. Has there been an official response from Exedy re: this noise and what we can do to help remedy this?
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Old 04-29-2010, 08:09 PM   #154
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Quote:
Originally Posted by BlueWagon02 View Post
I just started getting this same grinding noise after a new clutch install last week. On Tuesday of this week, I started noticing a wierd grinding noise under the car that happens when I lift off the throttle around 2-3,000 RPM. It doesn't seem to happen (or not noticeable) in the morning, but I can definitely hear it throughout the day when I'm driving (I guess after the car has warmed up). It seems to be something with the clutch, because when shift out of gear, the noise goes away. Also, there isn't any grinding when I'm on the throttle.

I guess I assumed wrong when I purchased the Exedy OE clutch kit that this was the same as the Subaru OEM clutch kit. Has there been an official response from Exedy re: this noise and what we can do to help remedy this?
I replaced my clutch a couple years ago with an exedy oem replacement and I have this noise too when lifting the throttle at mid rpm. I can't say if the problem started exactly when I replaced the clutch.

I even paid to have the tranny opened (I really thought something was broken) but they didnt find anything wrong, except the small disc thingy that prevents the fork to move over the third gear or something, it was broken. Replacing this didn't change anything.

I would like to know what Exedy says about it too.

The question I am more concerned about is if it can cause any problem and should I avoid conditions where the noise occur (for instance shift into a different gear when going down a hill so I'm not in the unsweet spot).

It does not sound healthy at all, I feel until we really know what is causing the noise in the clutch (if it is the clutch) we can't really have a clue if it can cause damage ?


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Old 04-29-2010, 08:27 PM   #155
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Quote:
Originally Posted by gopsu View Post
Here is response from ACT:

"The deceleration noise described has nothing to do with the surface or resurface since the clutch is fully engaged at the time. Chatter is a totally different subject, having to do with harsh engagement or shuddering only during engagement. The two subjects are often confused in discussions like this on the message boards.

First let's talk about chatter. This is something felt, and not so much heard. Clutch chatter is usually from the interaction of the friction surfaces (as long as everything else is ok). For instance the replacement discs from Exedy which are made in their Thailand friction material plant seem to engage more harshly than the OE friction materials (assumed made in Japan).

Deceleration noise (or other gear noises) occurs because of engine pulses being transmitted to the transmission gears. Of course the engine pulses (torsional vibrations) are influenced by a number of things such as compression, boost, timing, cams, etc. What normally helps to dampen these torsional vibrations out are the springs in the clutch disc and the heavy weight of the flywheel. In the case of the 06 thread you reference, keep in mind that the Exedy aftermarket replacement clutch is different from the stock clutch. The stock Subie (Exedy manfactured) clutch conforms to stricter standards and specifications. The OE clutch has a "wide angle damper" design which may or may not be the case with the replacement part. I don't know the exact details in this case without looking at the parts, but we have seen this all the time. Just because it says Exedy doesn't mean it is the same as OE. In some cases the automaker prevents the clutch manufacturer from offering the same part on the aftermarket, since they have a lot invested in testing, tuning the dampening, etc so they can only offer a similar part. Sometimes the clutch manfacturer changes the design on their aftermarket replacement parts to save costs.

A lightened flywheel can contribute to gear noise (there are several different types besides decel, btw), but you also have to consider what disc is being installed and that goes both ways. Also consider what changes have been made to the engine and tuning."
I just read the thread backwards and found this in the previous page and thought I should re-quote it.

One difference I do remember between the 2 clutches was in the springs configuration. I think there was double springs in the subaru one (like one small spring inside of the larger one) at each of the 4 springs locations, whereas I think in the exedy it was single spring (not 100% sure, but I remember there was a difference about the springs, that or the size of the springs)

Does the spings have somehting to do with the wide angle damper gopsu was talking about ?


Edit:

I have found my original post back in 2007 when I was wondering why my original clutch was different from the OEM exedy clutch, I did not remember the details at first but here is what I noticed at that time. I guess the noise have to do with the better dampening of the stock clutch.

Quote:
Originally Posted by frederik View Post
Hi,

My car is a salvage from the USA, I live in Canada. It's an 03 WRX sedan. Yesterday I replaced the clutch with an Exedy oem kit.

I think my old clutch was not the same as the Exedy kit, maybe the previous owner replaced it or something, and I'd like to know what it was. Or maybe it is an 02 instead of 03 ?
Sorry I have pics but I dont know how to post them. I'll try to figure that out. The old disk had 4 much larger springs, and inside of each spring there is another smaller spring. The new Exedy does'nt. The springs are partly green, and the steel housing for the springs is also larger in diameter than the OEM exedy, and not assembled exactly the same way on the disc compared to the new one.

If somebody want the pics I could email them.

Also, the pedal feel was much stiffer (I would say about 50-75% stiffer) and the friction point was much higher (pedal more "released") with the old clutch than the new Exedy, the new one engages earlier. My old clutch feel was also much stiffer than the others bug eye WRX's I tried before.

Here are some numbers I saw on the pressure plate :
3C17 AA570

And there is also "000" and "A78" written on 2 of the pressure plate "blades". Sorry I dont have the numbers written on the old disk, it is at home right now.


Thanks !

Edit again: Just to support what was already said previously about differences between factory and aftermarket Exedy clutches, I have found my pictures of the Exedy clutch that came on my car and the Exedy oem replacement clutch. It is clearly not the same design.






I also noticed the original pressure plate have a Denso logo on it.


Frederik

Last edited by frederik; 05-03-2010 at 07:44 PM.
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Old 04-30-2010, 12:39 AM   #156
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i reading this i understand that my exedy clutch(stg1) and act flywheel(12lb) where the reason for this noise i though was the wastegate. (2000-4500rpm) as of this past sunday they are fused together(30k on the clutch, and i don't dog the car it's my only one) and my car is on a trailer in my front yard. i think either the springs in the plate are broken or it's a cracked flywheel. it was spitting clutch like a diesel spits smog.

in any case im buyin a new setup. im thinking F1 stage 2 kit as i may go 16g in the summer. what do you guys think? or should i go back to OEM, same price(ish) from a friend at the dealership.

as far as noise, i don't care. i just want it to last ~100k like the last one did.
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Old 05-04-2010, 08:55 PM   #157
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I have found the pics of my worn original clutch and the exedy replacement and added them to my previous post. Pics are fun so I thought I should post them lol


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Old 05-04-2010, 09:12 PM   #158
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I wonder if the noise I had with my EJ205 motor will be different/less audible with my new EJ257 using the same Exedy Stg 1 clutch and ACT 14lb flywheel...

We shall see.
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Old 05-05-2010, 10:23 PM   #159
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Quote:
Originally Posted by frederik View Post
I have found the pics of my worn original clutch and the exedy replacement and added them to my previous post. Pics are fun so I thought I should post them lol


Fred
Yeah, apparently the spring design is different between the two. I wonder if that would have anything to do with the noise though, maybe the springs get loose inside their holds and rattle? I'll take pics of my exedy and post them here if there is any apparent damage or looseness when I pull my engine to swap into my other impreza. My noise is still like it was way back when and thankfully my transmission hasn't exploded.

Last edited by 2slofouru; 05-06-2010 at 07:51 PM.
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Old 05-06-2010, 07:29 AM   #160
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I am basically re-saying what someone said earlier in this thread about the use of the springs (cant seem to find it right now) but the springs are there to "dampen" the link between the engine and tranny.

My guess (that is really just a guess as I am no expert) would be that one of the sets of springs (possibly the softer ones?) is to dampen the vibration so the disc does not wiggle around with bumps from the engine reving, while the other is to absorb some of the more important shocks.

Anyway they are used to dampen vibrations and this is exactly the kind of problem we have so to me it is plausible that the difference in design can cause what we have.

The flywheel obviously have the same effect of dampening via inertia (smoothing out the engine revs and eliminating some engine "unsmoothness" before it actually reaches the clutch) so the theory is that replacing any of the 2 or both can lead to the noise.


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Old 05-06-2010, 07:53 PM   #161
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I understand what you're saying and it is plausible if the smaller springs keep the slack from causing rattle. That could be the reason mine is so noisey and why it took a while to start happening. It was dead silent for months though. I'm hoping to actually find clutch damage when pulling the engine, that would be better than engine and/or transmission damage and I have to buy a different model clutch anyway for my fwd transmission.
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Old 05-06-2010, 09:54 PM   #162
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Noise level had gotten low enough not to get bothered with for a while, then it's gotten noticeably worse after I jacked up the front of the car at the jacking point (under the engine) to change out the front sway bar setting. Aside from getting OEM clutch / flywheel, I don't think there is known fix for this issue...
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Old 05-07-2010, 11:11 PM   #163
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Quote:
Originally Posted by txl146 View Post
Noise level had gotten low enough not to get bothered with for a while, then it's gotten noticeably worse after I jacked up the front of the car at the jacking point (under the engine) to change out the front sway bar setting. Aside from getting OEM clutch / flywheel, I don't think there is known fix for this issue...
Jacking up the car should have no effect on anything in the bellhousing.. that is weird. Your noise just might be caused by something totally different
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Old 05-15-2010, 10:46 PM   #164
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Another person with the same issue and same setup, I might be getting a different clutch.

http://www.rs25.com/forums/f8/t13504...ml#post2095702
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Old 05-25-2010, 12:38 PM   #165
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Here's an update for my issue:

My stock EJ205 02 WRX motor went at 123k miles. I replaced it with a brand new 2010 EJ257 short block (Hybrid, using 02 WRX heads). During the swap, I was tempted to change out my Exedy Stg 1 organic clutch and ACT 14 lb. flywheel for stock units, since I am too sick of that awful deceleration noise. I was tight on funds, so I decided to just stick with it for my EJ257 swap. I was hoping possibly I wouldn't have as much noise with the new short block, but upon completion, it was still there. But, some good news came out of this. I decided to try staggering my tire pressure to 36psi in the front, and 32psi in the rear, and LOW AND BEHOLD, my deceleration noise is near GONE! It is probably 90% gone, and I can only hear chatter at very certain RPMS in 2-3rd gear. I was skeptical about this at first, but I'm glad I tried it, because now it's not nearly as loud! I'm loving my new engine and nearly no deceleration noise!
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Old 05-25-2010, 09:45 PM   #166
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I tried that and it didn't help with the noise, I'm hoping to be able to actually see the cause of the noise when I swap everything but might not be that lucky.
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Old 05-26-2010, 04:00 PM   #167
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Just recently put in a ACT streetlite flywheel with OEM STI clutch and pressure plate and no Deceleration noise or chatter. No CEL either so far.
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Old 05-28-2010, 09:42 PM   #168
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Here is what I did after my transmission sounded like it's going to fall off even after 36/32psi tire pressure adjustment (with Exedy replacement clutch + resurfaced flywheel).

1. Re-tightened transmission mount/cross member bolts/nuts (14mm)
2. Re-tightened Outrigger bushing bolts (17, 12mm)
3. Tightened all lug nuts again

Noise level has noticeably gotten better, although noise is still present.

Last edited by txl146; 05-31-2010 at 10:15 PM.
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Old 05-30-2010, 10:48 PM   #169
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Is anyone having chatter issues with the OEM Exedy clutches? Or is it just the Stage 1 organic clutches that people are having chatter with?
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Old 05-31-2010, 07:56 AM   #170
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Quote:
Originally Posted by Ryan314 View Post
Is anyone having chatter issues with the OEM Exedy clutches? Or is it just the Stage 1 organic clutches that people are having chatter with?
Yes, many people including myself. Mine has been in with the original flywheel for a year, was making some noise from day one. There were periods where the noise was very slight, others where I swear I must be dragging something under the car. Having the AC on often makes it worse.
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Old 06-07-2010, 10:30 AM   #171
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Wish I had found this thread BEFORE installing my lightweight flywheel and Exedy stage 1 clutch. The noise is TERRIBLE!

Has anyone here rebuilt their tranny and seen a difference? Or swapped to a 6 speed with the same clutch setup? General consensus is that most of the noise is simply bad harmonics. I'd like to upgrade to a 6 speed at some point, but I don't want the noise to follow me to the new tranny.
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Old 06-07-2010, 11:09 AM   #172
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^My noise is less audible now with my EJ257 block compared to my EJ205 block.
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Old 06-07-2010, 12:13 PM   #173
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I had a bearing replaced in the transfer case this past spring, and while in there I had an OEM-style Exedy clutch installed. Figured if I was there I might as well get it done with.

Sucks - the whirring noise of the bad bearing was replaced with the box of rocks decel noise of the clutch. I really think that the latter is worse...

Oh well. Next time things come apart she'll get the OEM parts.
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Old 06-07-2010, 12:21 PM   #174
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It seems ridiculous to me that the box of rocks problem is so sensitive to OEM Parts.

How did lightweight flywheels and "stage" clutches become so popular with these cars if it's so easy to make the tranny angry. Are people just living with this; or is it only a small sampling who have the box of rocks problem?
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Old 06-07-2010, 01:06 PM   #175
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^This "problem" / "chatter" isn't making the tranny angry. It's not harming the transmission whatsoever, even though it may sound like something bad is going on down there. All you are hearing is backlash on the gears, that's all. It's an annoying problem, not a serious mechanical problem.
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