clutch/gearbox issues....2005 gt jtd
Firstly apologies for a long post but this one has got me stumped....
Strange problem which im hoping someone may have some thoughts on!
Friend has a 2005 gt 1.9jtd with just over 100k on the clock. On Monday she was driving to work when after coming to a stop couldnt select any gears. Car was left and i went down to collect later. Car wont select any gears with the engine running but will start in gear and we managed to nurse it home. Felt first like a slave cylinder had failed as just couldnt select gears but with engine off would go through the box fine. (was a rattling noise coming from gearbox/bellhousing) Slave changed for a new one and bled out, action felt bit more positive but still a random rattling coming from box, sounds like a thrust bearing noise.....after some deliberation we took gearbox off. Evidence of a badly fitted clutch in the past (bolts missing and even the power steering pipe had been jammed and left in the box). Several small pieces of metal in the bellhousing and marks around it.
Old thrust was in a really bad way, loads of play and rough to turn, thrust had started to push through the clutch cover (bits of the thrust had started to fall off it) too.
The DMF has a little radial play (maybe 1/2 inch either way but no top to bottom play so was deemed fit to carry on.
New LUK clutch fitted (not a lovely job......) all put back together....clutch feels lovely and smooth but still cant select gear...its still dragging or at least thats what it feels like. after more deliberation a new master cylinder was fitted (another pleasant job) and although now the clutch action feels really smooth and light it still wont allow any gears to be selected with engine running!!
Ive bled the system a few times and am happy there is no air in it. The clutch arm appears to be at its maximum travel when the clutch is depressed.....it just feels like the clutch is dragging and wont quite disengage.
What are we overlooking?? something ive missed?? im loathe to pull the box off again but think thats my next course just to check theres nothing going on.
The car feels exactly the same as the day i recovered it, so nothing we have done has made any difference in the ability to select gears (though it feels a lot lighter and smoother than it did)
Any ideas???? DMF??? Gearbox??? Clutch (though cant think what!!)??