Thrust Washer Wear (Crankshaft End-Float)

A metallic knocking or clunking noise from the front of the engine, particularly when the clutch is depressed or released. The clutch may feel different -- pedal travel changes, engagement point shifts.

The A-series engine uses thrust washers to control the crankshaft's fore-and-aft movement (end-float). These washers wear over time, particularly on cars that spend a lot of time in traffic with the clutch partially depressed. When the thrust washers wear beyond specification, the crankshaft can move excessively, which eventually wears the rear main bearing housing and can lead to catastrophic failure.

1. 1 Check crankshaft end-float with a dial indicator -
2. 2 specification is 0.05--0.13mm. Above 0.25mm is danger territory. Replacing thrust washers requires splitting the engine. If caught early, it is a straightforward repair during an engine rebuild. If left until the crank has worn the block, the repair becomes much more expensive. Cost: $100--200 for thrust washers (as part of a rebuild), $2,000--4,000 for a full engine rebuild