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Long story short...my truck's manual trans started making noises that best described as "rocks being flung around inside the trans case" when you'd let off the clutch until it was fully engaged. All of you pin pointed it to the throw out bearing.
Had the entire clutch, pressure plate, clutch disc, throw out bearing, pilot bushing, etc. replaced and the flywheel resurfaced.
The noise is still there, not as bad, oh and when you push in the clutch it makes a clunk, let off it makes a clunk, and if you put it in neutral idling when hot the gravel sounds come back until the clutch is pushed in. It DOES NOT do the gravel noises when cold and the clunking is not as bad.
Someone told me on the input shaft if it's pitted or rusted or dirty, then the throw out bearing would get caught on it and make noises or it would be slamming forward/backward which is the clunking I'm hearing.
I've already checked the U joints and they're fine.
Does it sound like the throw out bearing is getting hung up?
It would really help if we knew the particular year, make, model, engine, and trans ....
But I have seen this type of continuing clutch problem, with the "clunk" noises ... after a catastrophic clutch failure, which was the cause for replacing the clutch ... because a tech didn't notice that either the clutch arm was cracked/flexing or the pivot point for it was loose/broken in the bell housing, resulting in a very erratic throw-out bearing movement. Also, I've seen the wrong clutch disc or pplate installed as part of a full replacement, or a defective disc or pplate ... cause these types of problems.
The diagnosis is going to be very dependent upon the specific vehicle and the details of the installation.
Sound like maybe a drive line moving in and out when the clutch is engaged and disengaged or a torque on the engine/trans mount.
I would put the truck on a hoist and have someone start the engine and engage the clutch while standing underneath to the side listening and observing any movement.
The noise would be more noticable this way.
Surprised that the shop did not do this first before doing all the clutch work. May not have needed all the replacement done...then again I did not see the old parts.
Any small nut or bolt would have left some evidence of nicks in the bell housing etc.
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