Please help poor Toadus - Gearbox noise

[Toad]

I just fitted an XSi box with a Quaife atb lsd. It's freshly re-built by Mankee. I've also got a new clutch kit fitted, which was put on about 2 weeks before this box got fitted. I had no issues while my previous box was on...

Since the XSi box went on i've got a metallic tappy noise coming from near or in the gearbox. While idling, if you press the clutch pedal down, it goes away. However, when you're on the move, it doesn't matter if the clutch pedal is pressed down or not, or what gear you are in, or even if you're in neutral, the very same metallic tapping noise happens. It's only once you reduce your speed under 5mph (ish...) AND press the clutch pedal down, the noise goes away. What's also odd is that the noise doesn't speed up or slow down from the likes of doing 20mph or 40mph. Just once you slow down to around 5mph, the tapping frequency quickly reduces and the noise goes away.

There's some other weird stuff happening. Sometimes on the overrun, just below 2000rpm, you hear a metal scrape noise! Like something has scratched my exhaust manifold. And when turning the ignition when the engine is cold, you hear a metal rattling noise as if something is very loose.

Any ideas???

[unreal106]

is it the inspection plate on the underside of the box? may have been bent?

also release bearing i know it has been said before but worth a punt?

[Ryan]

I thought the box had been used since the rebuild?

[Colin]

is it the inspection plate on the underside of the box? may have been bent?

also release bearing i know it has been said before but worth a punt?

I agree with this :y: maybe the plate is loose.

[Toad]

is it the inspection plate on the underside of the box? may have been bent?

also release bearing i know it has been said before but worth a punt?

Is that also known as the flywheel shield? If so, that's been taken off for the moment.

[Toad]

I thought the box had been used since the rebuild?

Paul said it's only done a couple of hundered miles.

[Toad]

Here's a quick video, trying to give you guys an idea of the noise which it's making. You'll probably have to turn your speakers on quite high. I put my foot down on the clutch pedal a few times, so you can hopefully hear the noise go and come back a couple of times. The car sounds like a tractor! It's also worse when stopped on an uphill slope for whatever reason!

http://tinypic.com/r/15ds6c9/3

What do you think?

[jpsaxo]

Not tappets on your engine is it? maybe youve only noticed it since the box went on? just an idea. Also could be an exhaust issue, as the exhaust bolts to the box dont forget.

[Toad]

The noise is coming from the box Josh.

[jpsaxo]

Whip the oil out of the box and see if any metal shiz comes out of it

[jpsaxo]

The noise is coming from the box Josh.

Inside the box or outside?

[Toad]

Inside the box or outside?

Difficult to tell. I'm going to take it to a garage tomorrow morning for a little advice.

[AlexB]

I originally thought sheild
if that's off then i'd go and check both mounts and the 4 main box bolts just to rule them out
then it may be the clutch isn't aligned quite right

[Toad]

Yeah man. We'll have a good butchers tomorrow. These guys have worked on my car a lot so we might figure it out hopefully :)

[jpsaxo]

Its a strange one, i cant see it being the box, so its something you've not put back together quite right or disturbed by changing the box, it cant be that bad as it seemed to run spot on at the ring either way!

[Toad]

Yeah, when you're on the move, the gears go in nicely. It just makes a racket! :S

[AlexB]

Does your mani have the bracket for the gearbox so it bolts to the flywheel cover?
If so could be that rattling as with out the cover (and iirc you said it wasn't bolted up before so it won't have changed removing the cover) it allows the bottom of the mani to rattle about and hit stuff