It started with a fairly dull knocking sound, mostly noticeable at idle. If I depressed the clutch the noise stopped, so I was thinking anything from spigot bearing to something in the gearbox. Then I noticed I could stop the noise by simply moving the clutch pedal a few millimetres, then the noise would return, then stop briefly when I released the clutch pedal.
Turned out it was the clutch pedal relay shaft that fits between the chassis rail and the gearbox. I fitted a new one of these when I replaced the clutch last year. Thing is the new one has poor bracket alignment where these are welded to the centre section. Result was oval wear to the tuffnel bearing that fits into the gearbox side cover plate. Another case of 'new' parts being poor quality I think.
Fitted the old one back in there, sorted. It's amazing how loud a tiny rattle/knocking can be, if it gets transmitted into the chassis leg!
So I am now enjoying the exhaust burble at idle again, without the noise that sounded like something expensive was about to break.
