I need some wise advice from the Guru's on OBS Clutch replacement.
My dual mass flywheel was starting to have some issues after 186,000 miles, So I had my local shop who I've used for years on major things that require tools and lifts that I don't have. Anyway, I asked that the dual mass flywheel be replaced with a single mass, along with a new clutch, throwout bearing, shift fork, slave cylinder and master clutch cylinder. When I picked the truck up the clutch pedal was so easy to push that I thought something was wrong as I was used to a heavy push on the old clutch. Upon driving, I noticed a loud noise coming from what I assume is the clutch/throwout bearing. When I slow down to a stop sign or pull into my driveway, I get a loud grinding noise. If I push the clutch in the noise goes away. Even when I let off the gas I get a howling / grinding noise. To me this is not normal and nor should I expect a new clutch to make noise like this. My old clutch never made any noise while slowing down. The shop used a NAPA clutch kit. I need to hear your thoughts on what maybe the cause of this awful noise. I can't accept "clutches make noise, that's normal" To my mind that is BS.

I need some direction on which questions to ask and what may have gone wrong.
Thanks for your thoughtful advice in advance.
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Sounds like you are hearing what is known as gear roll over in the transmission. The dual mass fly wheel dampened those. Over filling the transmission by 1 quart of fluid helps to quite down the noise. Fill the extra quart by removing the shifting lever, and fill threw the opening.

 

Have you taken it back to the shop and let them hear it?

 

If you determine it is gear rollover, which is somewhat normal at low speed or in too high of a gear. You can try different fluids to reduce the noise.

I bought my truck 8 years ago with a good amount of gear rollover noise. The fluid was unknown to me so I put Amsoil in. That helped quite a bit, but I tried Redline MTL. That helped a lot more, but the transmission seemed too notchy when shifting, especially when cold. I tried Redline High Temp ATF which is a hybrid gear oil and ATF and the gear rollover is 99% gone.

Very pleased with the Redline High Temp ATF and gave away a case of the MTL to another FTE'r for them to try.

 

Can you post a video or audio clip? Also, how are you normally driving it?

Mine is full of Redline D4, five quarts. It is the S5-47 variant if matters. MTL works very nice in the 265/6 Getrag in my '85 BMW, would imagine a bit better than the D4.

Thus far, I am in agreement with others that the noise is normal. You can check slave travel easy enough with a helper. May as well verify you have good pedal box bushings!

 

thanks for the suggestions. I will try the Redline High Temp ATF and report back.. I may take a week or so to get back around to changing out the trans fluid.

 

Did you get a chance to take it back by the shop to let them hear it?