New Clutch Kit Noise

[Nickslick]

Hello Everyone,
I'm new to this forum but have used it many times to figure out vehicle issues so thank you
What brings me to post today is an unusual issue I have following the installation of a new clutch kit (clutch, pilot bearing, throwout bearing, clutch release plate) as well as a new dual mass flywheel in my 05 Liberty sport 3.7liter. When starting the engine a very loud unsettling sqealing noise comes from underneath the vehicle. It isn't consistent either. It kind of chirps too while fading in and out resembling worn serpentine belt sound. Sometimes there's a short break in noise were the vehicle sounds perfectly fine quickly followed by the cringeworthy sqeal. I've been told it could be the pilot bearing is possibly wrong size. I've also read other sources saying that the clutch could be facing wrong (no springs in clutch nor any indicator of which side is correct). Parts were also pre-lubes. I lubed the splines and TO bearing face aswell. Flywheel face and release plate contact surface was cleaned with brake cleaner prior to installation. Could some surface rust accumulation cause this? As you all can probably imagine I'm somewhat dragging my feet about dropping my trans again. Keep in mind I'm also not able to get transmission in gear at all but I've had issues with my hydraulic clutch (new clutch master slave cylinder has been ordered). I would definitely appreciate your insight. Thank you.

 

[Billwill]

Is this an OEM Clutch kit?

I know my 2002 Export CRD 5 speed manual has the flywheel with a curve in it...to match the curve in the correct clutch plate.

This means that "flat" clutch plates cannot be fitted and the flywheel cannot be machined down....only small groves can be removed from the flywheel with Emory Paper.

Same applies to 2005 KJ.

So you can place a flat ruler across the faces of the plate and flywheel to see if the plate is fitted in the correct way.

The clutch Master Cylinder, Slave Cylinder and connecting tube come as an assembly pre-filled with clutch fluid...at least it did on my 2002 CRD. So I do not know how we are supposed to drain the system and replace the fluid.
So what I do every so often is to unscrew the reservoir cap and using a large syringe I pull out as much fluid as is possible and the fill up with new fluid up to the correct level.

You can download the 2005 Jeep KJ Service Manual here if you do not already have it:

www.colorado4wheel.com/manuals/Jeep/KJ/

 

[Nickslick]

Is this an OEM Clutch kit?

I know my 2002 Export CRD 5 speed manual has the flywheel with a curve in it...to match the curve in the correct clutch plate.

This means that "flat" clutch plates cannot be fitted and the flywheel cannot be machined down....only small groves can be removed from the flywheel with Emory Paper.

Same applies to 2005 KJ.

So you can place a flat ruler across the faces of the plate and flywheel to see if the plate is fitted in the correct way.

The clutch Master Cylinder, Slave Cylinder and connecting tube come as an assembly pre-filled with clutch fluid...at least it did on my 2002 CRD. So I do not know how we are supposed to drain the system and replace the fluid.
So what I do every so often is to unscrew the reservoir cap and using a large syringe I pull out as much fluid as is possible and the fill up with new fluid up to the correct level.

You can download the 2005 Jeep KJ Service Manual here if you do not already have it:

www.colorado4wheel.com/manuals/Jeep/KJ/

Yes. It is an OEM spec clutch kit from Powertorque. And OEM spec dmf from Brute. I'm unaware of any such reason why the clutch and flywheel shouldn't fit together unless there's a factory defect. All parts appeared to be in good shape. I will try checking the flywheel.

 

[Billwill]

If you go to Section 6 in the Jeep KJ Service Manual I gave you the link to...they explain this Convex flywheel etc.

They then have a list of possible clutch problems with advice on what actions to take.

I would advise that you first read up on possible problems and fixes before taking it all apart again!