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I'm at the pub now, but have some photos that will help to prevent anyone making the same mistake, and info on a patent pending clutch centralising tool....

Clutch plate was wrong way round. All ok now though, time to get ready for the MOT!

FRODO LIVES!

Ah brilliant! 5.00 on the dot, the rain starts :( Like I needed soaking wet to be added to the list of my woes!

Hmmm well I'll be up there in an hour, and will take some photos. I have to get it right this time!

quote: Originally posted by mattmayatt Silly me , one side has fly wheel printed on it :) I need to check for that, I am now worried that in fact I have the plate the right way round, and the problem is something else :(. The manual states " When refitting the clutch driven plate the...

Congrats, and welcome to the forum! You'll get all the help you need here to enjoy your van!

Yeah! I was by my lonesome, trying to wiggle the gearbox, and twist the driveshaft with my feet to align the splines, but no joy!

I tried this with Frodo, but it was too stuck. Took a couple of taps with a rubber mallet to get it off.

Well discretion is the better part of valour! The light started to go, so I called it a day. The gearbox was being a bitch to get back on, just wouldn't slide back on the shaft. After several tries I gave up, secured then engine, and will try again tomorrow. As long as it doesn't rain too much...

Stripped it down again - an hour and a quarter! Ok, it looks like picture 20 on the clutch guide "noisy clutch" section. I guess that means I fitted it the wrong way round! On the bright side the damage looks to be superficial so I am going to go ahead and rebuild. If I can get it all done...

quote: Originally posted by commeracer Whatever it is, its your fault for taking the box off :D "You,re only supposed to blow the bloody SLIDING doors off" Grrrrrr! Wait til I get my hands on you!

Panky, yeah I have thought about that possibility, the longer side should face the rear shouldn't it? Chris, no I remembered to fill up the gearbox - in fact I had filled it up last year and was gutted to have to drain away beautiful golden oil when I took the box out! Looks like I may have to...

Probably Panky.....

Hi Panky, I should have mentioned that the diff was changed. Colin, I can't be certain, but I think Tim is probably closer to the money, I just can't understand how and why!

It's def not the diff. It only happens while raising or lowering the clutch while in gear. In neutral there's no noise, and once the clutch is engaged/ disengaged there's no noise. I can get all fwd gears and reverse and the noise is there for each of them. Once you are moving, the noise goes...

The slave cylinder is in the correct palce now! I think you could be right though, it does sort of sound like lots of things in distress in a row! The only thing is, it only happens when a gear is engaged, I can push the clutch up and down in neutral and its fine. :~ I think I am going to have...

Right. Frodo is all back together, and the clutch is working, BUT, when it's in gear, and you slip the clutch, while moving off, or coming to a stop, it makes the most awful noise! It soundlike a ripsaw going though wood, and sort of similar to the niose you get if you try to engage reverse...

Yeah, I hear it helps prevent stalling!

Yeah I know - last time I listen to you lot! I was amazed how rusty the plates were, but Frodo has hardly moved for the last two years. But it's nothing a quick sanding won't sort out, and then I'll give them a coat of wd40 to stop it happening again. (joke!)