Okay, so i recently swapped a 302 in my 92 F150 that had a 4.9 with 5 speed transmission from a donor 95 F150 that had an automatic. I had to get the bigger flywheel to match the 302 motor with my transmission so i did that. Now here's the thing, when my truck is started there is no noise at all. 5 minutes or so after it's warmed up you start to hear a metal on metal grinding sound that gets louder with revving. When you push the clutch pedal in it does not change it at all. Truck goes into gear and shifts just fine although it does slip a little when accelerating at times. So i decided to tear it apart and put in a new clutch, throwout bearing and slave cylinder. Went to the 11" clutch to match to the 302 bc i only had the 10" when the 300 was in it. When i dropped the transmission the pilot bearing was shot so i thought well there was the problem so i put a new one in along with everything else and even took the dust shield, plate off between the motor and transmission thinking the flywheel was rubbing that. Well after everything went back together I started the engine and bam, silence and everything was okay.........But another 5 minutes later and the exact same sound is back. I dont know how to explain other than it sounds like a disc brake when its worn out with a metal to metal sound. It does it at idle in neutral and in gear and matches then engine rpms when i rev it up. And like i said it slips in acceleration through gears but goes into gear and takes off fine. I am really lost and have no idea what could be causing this. Any help please, i am so tired of messing with it only to be disappointed again and again. And by the way i did put a new starter on for the 302 because the original for the 4.9 didnt match so in case you were thinking that its not it. Thanks for any help you can give me!

 

When you ordered the replacement starter, did you specify for a manual transmission? Even if you have the correct starter, it could be defective and the drive eventually works it's way back against the flywheel.

 

Yes it is for a manual, I have ruled out the starter bc it is new along with flywheel and there is no noise during startup or directly after. Do you think an overfilled clutch master cylinder would cause my throwout bearing not to release all the way thus causing my clutch disc to soon somewhat freely when the pedal is released or clutch is engaged. Or am I just wishful thinking an easy fix bc I do remember filling the reservoir almost to the top

 

The amount of fluid in the resevoir would not have any affect on clutch position however, could the slave cyl be installed wrong?

 

I've read that too much fluid in the reservoir would cause the throwout bearing not to release because the fluid pressure on it has nowhere to go. Slave cylinder is installed correct because the slave cylinder/release bearing was all one piece. Im just totally stumped and this metal on metal grinding noise can't be healthy so the truck is a sitting duck.

 

If after the noise starts and the position of the clutch pedal (up or down) doesn't change the sound, I don't think it has anything to do with the throwout bearing or the master cylinder.

I wouldn't rule out the new starter, NEW= Never Ever Worked, well it does start the engine. There was a guy on here just a few days ago, we convinced him to remove his starter and get a pull start before he tore everything back apart again, and it was his starter making the noise.

 

As far as filling the master cylinder too full, there should be a rubber diaphram about an inch or so deep that you insert in the reservoir before screwing the cap on. Even without that I don't think it would cause the noise in the slave cylinder.

 

Well what would cause the starter to rub the flywheel only after it warms up. And the noise also goes away when under acceleration or under power when grabbing another gear but starts the noise again when I coast or let off the accelerator? I bled my line again and out the fluid to the recommended level so it must not have anything to do with the throwout bearing bc it has barely any force on the pressure plate when I checked it through the inspection hole with a prybar

 

This makes sense but what would cause it to only rub after the truck is warmed up? The noise also goes away when im driving and I get on it in any gear but then immediately comes back when I let off the gas.

 

As far as rubbing only after the engine is warmed up, the starter drive would kick out as it should when the engine is started, but eventually vibrates back to the flywheel or possibly be heat related. As far as the noise going away when you speed the engine up, the speed would force the drive away from the flywheel.

Now note this is all a theory. The bottom line here is DON'T RULE OUT THE STARTER AS THE CAUSE OF YOUR NOISE UNTIL YOU HAVE COMPLETELY PROVEN OTHERWISE BY SWITCHING STARTERS OR REMOVING THE STARTER AND DOING A PULL START.

 

I get its a theory and im not saying you aren't right, im not putting you down in any way, was just asking if those symptoms I had would also be a starter issue or if you ever heard of it

 

No I never heard of this happening before with a starter, but anything is possible with a new, newly rebuilt, or otherwise replacement part. I'm just saying I would eliminate the starter as the cause of the noise, before tearing anything farther apart again. Good luck. Kindly keep us posted.

 

Ok, I will try this tomorrow. Do you think this could have anything to do with the transmission internally? I would hope not. Just really not sure what else could be rubbing. Running out of things to check

 

This is a longshot but is the air pump still on the new 302?

 

If it was internally in the transmission, the noise would stop when the truck was at a dead standstill AND the clutch pedal was pushed down. Everything inside the transmission, including the input shaft would then be stopped.