G'day guys and gals, I have a problem with my clutch in my newly purchased clubman........ It grinds every time I go from 1st to 2nd (depending on the revs I'm doing to severity) and also 3rd. It is worse when going down from 4th to 3rd to 2nd. it is a mini k box and engine..... I don't know what the go is I have tried a different arm with less wear, no change changed master cylinders no change and I even bent the arm to see if that would work still no change. The clutch isn't slipping at all and i pulled the bell housing apart just to check everything was ok replaced the thrust bearing and the shaft thing that the thrust bearing is on and changed the flywheel and pressure plate and there is still no change. Last thing to do is change the slave cylinder. I have bled the system several times and it doesn't appear to be leaking at all and checked the Clevis pin for wear and it's pretty good. Adjusted the little 7/16 bolt on the bell housing each time as well. What's your ideas???? What's wrong and how can I fix it :'( it's a really bad feeling when you grind the gears not to mention its wrecking my box.... Any help appreciated.

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1964 smooth roof panel van
1967 Mk 1 X-Police cooper s
1970 mini k
1975 leyland

Ok so if you are in 1st, with the clutch engaged and the foot off the brake, does it crawl forward?

If so, then the clutch isn't operating correctly, and dragging. Based on the work you've done already, that seems unlikely, but worth testing anyway.

What it sounds like to me is tired or stuffed synchros. To test this, do a double de-clutch changing down, so clutch in, into neutral, clutch out for a second, then clutch back in and into the lower gear. If it doesn't crunch (or as much) doing this, then I'm afraid it's a synchro problem, which is an engine out and apart job

cheers,

Jacob

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'72 Clubman Van - 1022cc, 295 head, 731 cam - Daily Driver
'69 Morris 1100 S - Dinged by a bus, in shed under repair
'64 Morris 1100 - Early 1100, long term project

I was thinking it was a work out synchro...... But wouldn't it jump out of gear if this were the case????? As it doesn't.... And no it doesn't creep forward at all.... Was hoping I didn't have to pull it all apart. Lucky I have the next few weeks off

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1964 smooth roof panel van
1967 Mk 1 X-Police cooper s
1970 mini k
1975 leyland

Jumping out of gear is due to a number of factors but worn synchros aren't usually one of them. No creep, ok try doubling the clutch and see how you go, but it is sounding like you have synchro problem.

Grinding changing up is not so common, remote or rod change? Do you know any of the history of the 'box?

edit: oh and do you have to force it into gear, or does it go in okay but grind?

cheers,

Jacob

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'72 Clubman Van - 1022cc, 295 head, 731 cam - Daily Driver
'69 Morris 1100 S - Dinged by a bus, in shed under repair
'64 Morris 1100 - Early 1100, long term project

Lot doesn't jump out of my of the gears. It is also a solid change box and I don't know the history of it. Looking like I may hve to pull my box out of my unregistered mini as I know it's a1. And I have to force it in doesn't go in unless I have the revs right or force it in.

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1964 smooth roof panel van
1967 Mk 1 X-Police cooper s
1970 mini k
1975 leyland

needs a rebuild

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did I tell you that I won a trophy?

Who pulled the clutch out of it huh lol

You mention it crunches into gears and you have to force it into gear, still sounds like clutch dragging or a very remote possibility of primary gear fault, but that is rare. What happens if you try to select reverse?

I can find all gears when stationary and select them no worries. Changing down is the worst with second being worse than third. If I don't force it it'll just keep grinding.

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1964 smooth roof panel van
1967 Mk 1 X-Police cooper s
1970 mini k
1975 leyland

It's a bit hard diagnosing stuff like this via messages.
So, if you get in car, put it in neutral and start it up, then after pushing clutch in you go to select gear, say reverse**.
What happens?

** reverse doesn't,t have syncro so if there's problem with clutch releasing it'll crunch.

Sounds like 2nd gear's synchro ring is stuffed, it is first to go bad. Rebuild time...
Replace the 1-2 synchro hubs springs if weak, as they can give similar symptoms. Minisport SA has stronger ones.

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.