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So, to review. The thrust washers fit perfectly, 0.002inch gap by feeler gauge. Throw-out bearing is perfect: no play, spins nice. Like new. I am in the process of putting it back together, and doing some cleaning as I progress. I realize this rub inside the flywheel housing - see photos. The pressure plate is rubbing the raised circular bump just below the crankshaft, inside of the flywheel housing where, on the other side, is the idler gear needle roller bearing. Why do I have this clearance issue is now the question. Sorry, I can't seem to drag photo into the post.
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With the block on an engine stand and the crank vertical, you can use a prybar against a web to move it up and down.
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Don't rely on the feeler gauge.
Clean everything up, and check the end float with a DTI gauge DRY - don't have any oil or grease in there as the reading will be wrong.
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So now I'm perplexed as to what the source of the growl. I'll replace the throw-out bearing, just because. Not all is lost. This engine always leaked, so I can fix that and give it a nice paint job. Sigh.
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The thrusts on a Mini crank are not pressure fed, they're lubricated by leaking oil from the centre main.
Starting the engine with your foot on the clutch (like a modern car with it's 'safety' feature...) is a dreadfully bad thing to do as there is effectively no oil on the bearing face. With a heavy race clutch spring it is possible to wipe out the thrusts in very short order.
Sitting with the car in gear and the clutch depressed at a junction, will do a similar thing - I try not to have the clutch down for more than 5-10 seconds without releasing it.
Good luck with the strip down - we're here with sage words of advice as you go.
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Could be the thrust bearings.
Watch the crank pulley as someone presses the clutch with the engine running - if there's something icky going on it will move in and out.
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