1k revs to 2k revs rattle

[Martyn84]

Im just a decorator so weight is no issue. Im sorted now anyway. Got a new 3 piece luk clutch and a gearbox out of same year / same size engine Thanks for all your help guys

[Martyn84]

Just let everyone know it was the gearbox As said i also had a new clutch put in Van is running spot on now. Cheers

[liteace]

How do you know 100% it was the g\box making the noise if you have changed the clutch as well ??

[Martyn84]

Took mechanics word

[jansu83]

My Connect had a clutch replacement last week, and it cured the rattle on mine. Here's the old driven plate and it's springs (in Finnish though...):

https://www.youtube.com/watch?v=8Lb74dP3EuE

[gt_addict]

It wouldn't have been the box it would've been the clutch plate as many others have found out. Did the mechanic say it was the gearbox as his diagnosis by any chance?

[no1toker]

ive changed the clutch on mine a couple weeks ago, 2006 tddi single mass flywheel 54k on the clock, now the rattle noise is slighty worse if not more so, im thinking box now as the clutch didnt cure it

[s.s.79]

hello ive got a 09 sport and have a rattle noise at same rev range.
ive had a new clutch about a 2 weeks ago and hasn't made the rattle go away

[gt_addict]

Check heatsheilds for any rusted through fixings.

[jansu83]

My Connect had a clutch replacement last week, and it cured the rattle on mine. Here's the old driven plate and it's springs (in Finnish though...):

https://www.youtube.com/watch?v=8Lb74dP3EuE

My rattle sounded like loose heat shield and after drivin a few thousand miles more, it was like leaking exhaust sound with these worn clutch plate springs. It could be heard better with left side window open. This kind of rattle was heard only when accelerating and engine revs between 1500....2000 rpm. The noise was very loud between 1700...1900 rpm when accelerating on any gear. The harder I accelerated the louder was the "leaking exhaust" sound but no sound if on neutral gear or clutch pressed and revving. And no sound at all when revs got above 2000 rpm. There was also a very short rattle when engine was started and one "clank" when engine was turned off. These could be heard when I didn't press the clutch and turned the key. If the clutch was pressed, these sounds couldn't be heard at all. With new clutch these were all gone.

Now I have a new clutch and the loud rattle is gone, but when I listen carefully I still can hear a small rattle from clutch or transmission at lower rpm like 1000....1400 or something. It can be heard when accelerating or engine braking with 1st and 2nd gear (at least). I knocked my lower engine mount (between transmission and front subframe) with small rubber hammer and found a little play from there. I took it off and noticed that there is play between smaller bush inner metal and the bolt that goes through it to the transmission. I don't know for sure but it would be possible that this small rattle comes from the bush metal knocking to the bolt, since there's nothing that actually tightens the bush to the transmission or to the bolt. The design could be better at this place. It could easily make a noise even with small play between the bush hole and the bolt.


EDIT: This is the place I mean. Picture taken from below the transmission.



Somehow I believe that if the transmission was rattling from inside like this, I wouldn't have got this far with it. The transmission feels very good and works like a charm. My van has 230,000 km (about 143,000 miles) on clock and clutch was replaced at 228,000 km