UP date!
All back together last night. All done. New clutch, pressure plate, thrust and needle bearings and flywheel bolts. Also new gearbox rear mount.
Went for a test run. Was quiet for about 1/2 miles then heard a soft click that turned into a louder click as the car warmed up. The good news is that I now have a good spare clutch.
The bad news is that engine will be coming out again. I can only conclude that it is from the gearbox. When out I had a look in there and also tried the slack in it between input and output shafts in gear. It was slightly more that of a very low mileage mint Anglia box that I have. I was of a mind to change it but figured I would never know what the culprit was. Also me and my hands are not going to give the force required to make the noise.
I can only conclude that the new cold oil screened/cushioned the noise until it warmed and then the less viscous oil allowed the click to return. I am wondering if it is associated with the action of going through the lay shaft. I did that rocking thing in gear with the engine stopped and could hear the noise (albeit) not as snappy. Will try in 4th tonight and also take it for a faster run and try and make it do it on and off the throttle in that gear. Last night I only went on estate roads and could get the noise in 1st, 2nd and 3rd. less dramatic as gear goes higher and torque is less. It just feels like something taking up slack after the car is moving. It sounds like it is definitely coming from around the gearbox/bell housing area. I was suspecting the prop' shaft UJ?s again but they are new and I checked them and found nothing. Diff is also refurbed and does not sound like it is so far back. The heat thing must tell me something. I think I may drive it while I dig out a spare box and get it ready.
Good new! I did a mod to the clutch slave cylinder mount on the bell housing. For some particular reason the slave cylinder was a sloppy fit (in this particular housing) and slides a good 2 mm or more fore and aft?. I drilled a hole in the bottom of the bell housing and tapped it. I know have the cylinder sat on the circlip with the bolt holding it firm and a lock nut to prevent the bolt moving. Took about 5 minutes and the clutch pedal feels mint. The cylinder was moving with the action of the piston and the return spring. I could have got a shim but this seemed easier and more immediately easy to do.
Another thing I did was to repair the wear in the clutch ?D? shape thing that sits on the thrust ring and fork. This creates a lot of play if slightly worn. Bite point on pedal is much higher than it was before.
Any suggestions welcome about possibilities on gearbox being the culprit. I don?t know much about them and what might give this sort of effect.
Mike