Snap, crack, and popping noise & slipping clutch...

[ajbremer]

December 25th, 2010 Oklahoma, USA

Hello everyone,

Why am I trying to do a clutch job on a 1991 Ford Festiva in windy, freezing, and cloudy weather on Christmas day? I don't know, I guess I wanted to stop my curiosity.

Anyway, I think the snap, crackle, and popping noise (on top of the slipping clutch problem) is actually a transmission bearing problem. Check out the video:

http://www.youtube.com/watch?v=N37hSwjvGyo

Please let me know if I'm on the right track - what do you think the problem is?

By the way, the fly-wheel surface doesn't look bad...

al

Allan J. Bremer

[doylerl]

I don't know about the play in the shaft but the cracking and popping sounds like a cv axle problem to me.

[xaero_81]

When I recently replaced my transmission the shaft didn't move like that. I would also think that you'd be leaking fluid by output shaft with that much play. Probably could get a used one from someone on here for pretty cheap.

[Rocketman]

Yeah that's not supposed to move like that. The seal is probably shot (due to the bearings) and leaking fluid causing your clutch to slip, even though it appears the disk has minor wear

[ajbremer]

Thanks guys, but what about the snap-crackel noises?...

Thanks for all of your answers, they've helped me a lot.

The fluid that you say could be leaking into the clutch cavity of the transmission is for sure. Now that I've looked into the cavity, I do see that it's covered with a slight oil/dirt film.

Well, now I'll be looking around for a 5-speed tranny, here and everywhere. By the way, is it worth taking it to a transmission shop or would they not have these parts?

What do you think about me using clutch parts that a friend of mine gave me. The clutch parts that came out of this transmission look even better than the used parts he gave me. I guess it's just a good idea to go out and buy a new clutch, now that I've done all this labor removing the transmission. Is it true to say that a clutch disk is good until the grooves are worn away?

I still would like more comments from people who have come across this situation. Thank you for all of your help...al

[ajbremer]

I forgot to mention the cv-joint bearing...

Oh ya, I forgot to mention something that may be major. As I was pulling out the drivers side cv-joint, a big bearing came out with it. I was surprised by that because I didn't think that was supposed to happen. I left it alone on the end of the shaft and thought that I'll just put it back in that way.

Could that be a sign of a problem and/or could that be what is making all the snapping and crackling noises? I got a pretty good picture of it here, please take a look:

http://www.mrmachinist.net/cv.jpg

[denguy]

That's the worst thing I ever seen.

[xaero_81]

Get a new cv shaft and a new drivers side fender. Lol.

[GenevaDirt]

Oh ya, I forgot to mention something that may be major. As I was pulling out the drivers side cv-joint, a big bearing came out with it. I was surprised by that because I didn't think that was supposed to happen. I left it alone on the end of the shaft and thought that I'll just put it back in that way.

Could that be a sign of a problem and/or could that be what is making all the snapping and crackling noises? I got a pretty good picture of it here, please take a look:

http://www.mrmachinist.net/cv.jpg

that is only part of the cv shaft....you need to replace the whole thing .....not put that back in.

[lessersivad]

I think I'd be checking the pilot bearing also.

[Aaronbrook37]

that is only part of the cv shaft....you need to replace the whole thing .....not put that back in.

This +120912908409124.

[econoaddict]

I will second the new clutch kit. disc, pressure plate and throwout bearing.
What you did by pulling on the cv shaft was seperate the inner joint, you are seeing the "inside" of the joint. I would just replace it at this point. If the other axle has any splits or tears in either boot replace it as well.

[scitzz]

That trans is shot for the average DIY'er. I have a bad five speed next to the shed that does the same thing. The input shaft that you move around so freely is likely snapped. That is what is causing your clutch to slip. The clutch and pressure plate, judging by your video, could probably even be re used, but I wouldn't recommend it.

That said, if you can find a transmission shop near you that will divulge where THEY buy their parts, you may be able to replace some bearings, and even the input shaft. I can't tell you how many times I have been told that if I can get a standard trans out, I can rebuild it if I just try. I just have never tried....

The Festy four speed will bolt right in( I am using that setup now,) and it is my understanding that an Aspire 5 speed will work if you also get the front motor mount. The final gear is taller in those, giving better acceleration, and slightly less MPG.

If you do a tear down, please post a video! I have three bad five speeds in my yard, and I would love to get one back in my car!

[walth]

the shop manuals you find on ebay are out of this world extensive on the transmission rebuilding aspect. I haven't looked in my 91 SM yet but I know the 88 one I got ahold of I was blown away they'd go through so many details! With the help of the manual you shouldn't have any issues I would think.

best of luck to you getting everything back together soon and in great order.

I will say also, my left CV would POP*POP*POP*POP when I would turn around in my street. I replaced both axles and tie rod ends. In a general "replacing of the CV's" you'd want to make sure to replace one at a time as the gears and such inside could fall low enough not to be able to get the CV back in. and the seals are like 2-3 bucks a piece (and they ARE different for each side) and I'd recommend that to anyone while changing them out.

[denguy]

Keep car in neutral. If the trans turns inside with the shafts out the side gears will drop down inside out of place and I don't see how you can reposition them without taking the tranny apart. I would insert a piece of PVC pipe in after i pulled the shaft just in case.