2003 Picasso hdi gearbox/clutch issue

[mozzy]

depressed is not the word...
bought this picasso hdi got it cheap as it required a new thrust bearing......
1, removed gearbox, replaced clutch and thrust bearing, put it back together and car had very little drive, turns out the clutch i had been given was meant for a model with a dmf, mine is solid.
2, gearbox back out, new clutch replaced with correct clutch, also replaced clutch fork with a new one started car, lovely, press clutch lovely, the 2nd it is put into any gear im got a loud scoring noise which is only there when in gear wether clutch up or down (does drive but this noise was constant) seemed like a box fault so i went and bought a replacement guaranteed 42k gearbox (which i know is a goodun as i drove the car it came out of)
3, fit new gearbox, exactly the same noise is still there even on the newgearbox.

any ideas as im thinking the new clutch i have fitted must be the cause, the motor factors has given me a brand new clutch kit which i will be fitting tomorrow, but anyone else encountered this before.

so just to confirm it has had
1 new clutch
2 new release bearing
3 new gearbox
4 new guide bush (for release bearing to slide up and down on)
5 new clutch fork

any help or info greatfully recieved

[mozzy]

hers are some pics of what i encountered when i initially pulled the box out

[citronut]

who fitted all the new parts and did you engage the thrust bearing properly,

the amount of damage caused there it is not easy to tell what went bang first,

the other thought is were did the parts come from and what brand/make

[citronut]

just read you post properly,

if those picys are what you found when you first dismantled it, it looks as though the thrust bearing had worn through the pressure plate fingers, then smashed the thrust bearing and guide tube

[mozzy]

the clutch etc are all Valeo and brand new, not recon rubbish....I fitted all the parts myself.

the main issue is 2 gearboxes have been in the car and both are making exactly the same noises and I know the 2nd gearbox is perfect as i drove the car it came from, i then removed it myself and fitted it into my car with a brand new fork, new clutch, new bearing and alot of stress lol and its still making this noise.....

its certainly strange, so to reitterate

in neutral with clutch depressed= normal
in neutral with clutch pressed= normal
in any gear with clutch pressed and stationary= loud grinding/scoring
in any gear with clutch up and driving, = loud grinding which silences around 2500 rpm

whats weird is as i say it only does this in gear, wether the car is moving or not

[mozzy]

I have another new clutch kit which I will be fitting tomorrow so i have my fingers crossed it will solve it,

the car was an absolute steal, its a 2003 2.0 hdi 10 months mot, 2 months tax, is a bit scruffy and has done 210,000 miles (but have reciept for brand new replacement engine 60k ago so the original box has done 210k but felt nice and tight, but now have a new low mileage box in it.....I paid £160 for the whole car as the previous owner thought it was going to cost him big money to repair ......I bought the car for £160 and have spent £210 on parts and no labour costs as i do it myself. so hopefully i dont have to spend no more on it and i have a cheap runaround

[RichardW]

You have got the friction plate in the right way round....???

[citronut]

bit like the 02 1.8 16V PISSSCASSOOOO we bought for my daughter
we payed £100 quid with suspected head gasket gone,
the previous owner also said it had been useing lots of oil,
so we bought a good second hand engine, new cam belt kit, water pump, clutch kit and air con condenser,
she has run it for i think just over two years without a hitch

[Gibbo2286]

It seems to me logically that the new clutch is fine, even dodgy pattern parts don't give problems straight off, you know the gearbox is fine so the problem has to be aft of the gearbox, I'd suggest that you haven't fully engaged one of the driveshafts onto the diff splines and instead of turning the shaft it's bouncing over the ends.

[citronut]

do you know if this is a 90 or 110hp, if the later i think it would have come from the factory with a DMF,
in which case maybe someone has converted it to a solid flywheel over the years,

i have heard stories of people having trouble matching a second replacement clutch up with some solid flywheel conversions,

but as Gibbo says it sounds more like the fault is after the clutch in the drive train,

although if it were what he suggests you probably would not have any drive at all

[Gibbo2286]

Citro, as he says he's already got and fitted a known good gearbox I doubt the problem is in the box or the diff so logically it must be in the area of the driveshafts.

I'd guess that he hasn't got the mid bearing in the RH shaft bedded properly in place and that's stopping the driveshaft engaging on the diff splines,

He hasn't said whether he has any drive to the wheels so I'm assuming he still has it up off the wheels.

If he has drive I suppose it's possible the driveshaft mid bearing is knackered.

[mozzy]

It is a 90bhp, and as it says above, the grinding is there when driving ,

[Gibbo2286]

Silly question I know but have you put the correct quality and quantity of oil in the transmission?

[mozzy]

Im really greatful for all the replies and advice, I decided today to ignore my amateur mechanic friend who has been helping me alot in getting this sorted....he bolted the clutch up against the flywheel the other day and stupidlyu i assumed he knew what he was doing....obviously not, bloody friction plate in the wrong way round, i removed the box alone today, turned the plate around, put it all back together and it now drives perfectly.......i guess the saying "you pay peanuts , you get monkeys" is true....thanks again gents