I replaced my clutch with a new Valair organic 13” clutch, new flywheel, pressure plate, throw out bearing, bolts, pilot bearing, trans bushings and all universal joints on the truck. All was torqued to spec. The break in period ~200 miles went well. On Sunday ~250 miles in during the longest trip with the truck ~30miles this scraping sound developed only when the clutch is depressed. The video shows the friction disc trying to turn with the clutch depressed. Obviously I need to take the drive train back down but any thoughts on the why while I sit here banging my head on the wall? I called Valair tech support and talked to Gary Wolf before I had this video believing the friction disc was rubbing with the clutch depressed and he said that can’t be... needless to say I sent him a longer video of the impossible. To me it seems like the pressure plate needs more of a stroke to fully release the friction disc or is faulty. I have tried 2 other hydraulic units to no avail and confirmed with Valair that I do not need an upgraded hydraulic unit to run the kit I purchased. The clutch forked looked just fine and everything moves freely just this problem and of course it intermittent happening more while hot but has happened cold. The old clutch simply was worn and the throw out bearing was making noise. Also the truck runs and drives just fine but I’m not driving it regardless. Btw the two options Valair tech support gave was pull the clutch... a reasonable response or “wait for something to happen” I’m on day 22 of the 30 day warranty I’m not waiting lol. Any ideas while I begin to take the drive train down are much welcome. Thanks btw the truck is bone stock and is just a daily driver.

Update: I have the trans off but not the bell housing yet(started raining) the pilot bearing separated and sent pieces of its self every where. I’ll update again tomorrow when I have it all apart. The trans went together fine and stabbed in without any resistance and bearing is still in its bore so it wasn’t hit by the input shaft.

 

Even if it didn't release completely, the clutch disc's drag should be relatively smooth/consistent.

I think you have a piece of something between the facings.

 

Try bleeding the air out of the master/slave cylinders. It's possible they are not completely disengaging the clutch. Why it's making a noise as it drags I can't say.

Edwin