Need Expert Help - Smoking after replacing clutch!
 

Ok guys...I need some help here pin-pointing my problem. First a little background info...

My '88 SE non-turbo had the famous clutch/bearing noise due to the pilot and release bearings. I decided to do the work myself and spend a few days on my back. This was the first time I've pulled a transmission and replaced a clutch. Did my research .... figured "I got my Haynes, sounds fun".

Well I just finished replacing my clutch with a LUK RepSet kit (PepBoy's guys vouched for streetability and dependability). And of course I installed the new pilot bearing, seal, and release bearing. Used Castrol multi-purpose wheel bearing grease in all the right spots (says it's a NLGI#2 lithium and "resists meltdown at high temps"). Filled the tranny with GL-5 Valvoline Gear Oil 80W-90 "High Performace".

Now the problem...

Cranked her up once I got her put back together and lower. Purred like a kitten. But within 30 secs, I smell something burning...I guess like burning gear oil. My exact reaction....."SHIT!" Popped the hood and gray smoke is comming from the passenger side. I immediately shut her off. Waited about another hour and desided to take her out for a quick drive....maybe a little clutch fluid dripped on the exhaust while bleeding the system. Went out for a couple miles, drove fine, shifts smooth, no more bearing noise, bring her back to the garage..........still that slight hint of smoke and burning smell. Crawled underneath and see hints of smoke all along the exhaust. The bellhousing seemed a little too hot for just a quick ride.

So what could it be? I'm hoping just a little oil leak somewhere finding it's way to the exhaust. Could the clutch be rubbing like the pressureplate torque on too tight (don't see how, I followed all torque specs). Maybe I didn't the right gear oil or maybe there's too much? I'm looking for any thoughts you more experienced guys may have.

I'm just hoping I can still get to work on Monday haha.

Whats the famous clutch/bearing noise?
Mines makin a bit of a sound.....

Perhaps too much gear oil. You might also have an exhaust leak somewhere. Another thing to consider is that your front cover seal on the transmission might be shot. That would allow fluid to drip out and potentially get onto the exhaust. Just a thought...

well at least it isn't a burning clutch smell...that happened to me right after I installed a clutch, the damn POS slipped so bad that i could barely drive the car...put 6000km on it before i finally had money for a new clutch.....anyways you might have got some 80-90 or brake fluid on the exhaust. Hopefully that is all it it....I have had my transmission out 4 times in a 8 month period for various reasons and one time it did this when i spilled 8090 on the catalytic converter heat shield. Good luck.

Famous bearing/clutch noise...
 

Depress the clutch and hear spinning/scrapping metal in transmission/clutch area......release (throwout) bearing bad. Release clutch pedal and her spinning/scrapping metal.....pilot bearing bad.

Hope this clears that up.

Thanks guys for the quick responses! Keep 'em comming. Hoping I can get this resolved by sun-down tomorrow. Gotta say....working three days on this as a newby is a little tiring and frustrating. Yet definately learning alot. Better to do it yourself I say.

Any other thoughts? I know some of you experienced guys can add to this. Thanks again for all replys.

Ok...jacked her up this morning and checked my trans oil lever (level with the bottom of the fill hole - good) and checked for oil leaks. Didn't see anything hitting the exhaust. However, I did notice a drop of gear oil forming at the bottom edge where the starter mounts to the transmission. I'm thinking this is a big clue. Could this mean my front cover seal of the transmission isn't doing it's job? If gear oil is getting through, what damage if any is done to the clutch if left unattended?

Well I cranked her up and slid under the car. No other leaks and didn't see any smoke. Left it running for a few minutes and gave it some gas. I didn't notice any burning smell ..... that is not until after I shut her off. I still smelled that sharp (I hope burning gear oil) smell.

I've seen where RedLine has been recommended. I have yet to find any at Advanced Auto or Pepboys. Where is this stuff sold?

redline is hard to find .....motomaster 80-90 works fine though. Anyways, sounds like the front seal on your transmission may be shot. If oil is on your clutch im sure it can be cleaned off....maybe with brake cleaner but dont quote me on that as i have no idea if that would work. You can probably get a new seal for a few bucks. Good luck.

-zero

Thanks, Opistons. Took her for a drive today without any problems. There was only a slight smell of the oil burning. I think I'll just take it easy while I break in the clutch and just see what happens....crossing my fingers.