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Assuming a traditional design it is probably rust and if fitted with a clutch pilot bearing, the gearbox shaft could be seized into it meaning considerable force might be needed to remove it. I have known them to be so seized into the pilot bearing that removing the gearbox actually pulls the bearing from the housing.
It is the slave cylinder inside the bell housing. These are notorious in going out and it looks to be quite entailed. I found a video on it but it only shows how to replace the slave cylinder AFTER the bell housing has been removed.
You will need an 8mm, long barrel, socket plus an extension( to keep from busting up the knuckles) to remove three bolts that holds the slave cylinder to the wall of the bell housing. Once the old one is removed, get some bearing grease and grease down the shaft. this will allow for an easier mount and get it ready to have the bell housing re-assembled.
Here's the link, though it the music is kinda creepy....
If you have driven 26,000 without a problem I doubt it's related to the clutch replacement, but I think we need more info here.
Does the car make the noise multiple times during one trip (on and off as you start and stop)?
Can you hear it when you are parked in your driveway? The best thing to do would be to get out of the car when you hear the noise, pop the hood, and try to locate which part of the engine it is coming from. Then we can move on from there.
Your problem is probably that you have the clutch plate out of position and the clutch shaft is not being allowed to line up with the spigot bearing in the end of the crankshaft. . Get a cheap clutch aligning tool, loosen off the pressure plate bolts and align the clutch plate. Having done that retension the pressure plate bolts. Keep the gearbox evenly spaced around the bell housing as any misalignment will not allow the clutch shaft to engage in the clutch plate and the spigot bearing.
Idle is normally set a bit higher anyway for a cold engine. If the warm idle is OK when the clutch is not engaged and gearbox in neutral, then it points to some kind of severe friction in the area of the clutch throw-out bearing, which may be seizing up, or the clutch pressure plate fingers, one of which may be broken off. If the idle is the same, then that simply needs adjusting.
Is there any odd noise when the clutch is depressed, like a low growl? That will be the bearing. You could have someone listen next to the clutch bell housing while you work the clutch pedal, to try to localise it.
I think your gear box will have to come out, because I believe what you're hearing, is a damaged bearing....I can't recall if your car uses a pilot bearing, but I believe it does and that one would be a suspect.
Another of the bearing's that could cause the problem, is the clutch release bearing. If that has been over adjusted and is in constant contact with the pressure plate (clutch cover), it will give the symptoms you talk about.
As the box has been removed during the past, have you checked the gear box oil level?
If it's dry or the oil level very low, the gearbox input shaft bearing could be damaged.
I do not believe the noise has anything to do with the starter motor!
As the noise is obvious during idling, start the engine and while it's idling....With a very long screw driver, pin point the noise in this way.....Take off anything dangling from around your neck and don't wear loose clothing....Give your neighbors a treat, and if necessary.... remove anything that can get caught anywhere....
Take the long screw driver and place the business end in firm contact with the engine block behind the front of the bell housing, close to the starter motor and press your ear to the handle....You'll hear the noise....Now change the place to listen on top of the bell housing.....and then to the gear box side of the bell housing....If the noise is loudest in the front, then suspect the pilot bearing....Middle or top,...suspect the thrust bearing....With this one have someone press and release the clutch pedal while you listen for any changes in frequency ....Gear box side input bearing....
Once we know more about the problem, if you would like to tackle it yourself let me know and we'll go on from there....
Now put your shirt back on and wave to all your new friends....Best regards Johngee10
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