A few years ago I had a "4 speed" clutch which produced a clacking machine-gun like rattle if the pedal was depressed far enough to release it. Eventually I pulled it all apart and carried out the "grubscrew modification" to compensate for wear at the three lever pivot points. This solved the problem, but I can still get a slight rattle if the clutch is pushed right to the floor, especially with the engine and gearbox cold.

Hedd's explanation is the first I have seen that convincingly fits the symptoms - the rattle comes on quite suddenly beyond a critical amount of pedal depression. Maybe as the gearbox/bellhousing warms up it expands very slighty and changes the geometry ? Given that there are three slightly different levers just hitting or just missing two slightly different taper pins I imagine that quite a variety of noises can ensue, which will all be engine speed related.

Maybe a temporary fix would be to put some thick felt or carpet under the clutch pedal to limit its travel (assuming this is still far enough to allow disengagement) ?

Location: New Forest

Thanks
My problem is that the noise only appears when the pedal is fully down. All gears can be easily selected by only depressing the pedal slightly and then the noise does not happen. Its as though the clutch is being withdrawn from the flywheel too much (if that makes sense).
Cheers
Ade

I think your suggestion (same as Reckless Rat) to limiting the pedal movement will be the way to go after I've tried adjusting the clutch pedal. The pinch bolt looks quite easy to get at so will start with that.
I'll get the wife to operate the clutch while I go underneath and try and work out best way to adjust it.
Cant be much of a problem as its suddenly appeared and is definitely not getting any worse. If it was anything too serious I would have expected it to have manifested itself into destruction be now (fingers crossed)

Thanks
Ade

You could limit the movement quite easily by making a little stop that fits on one of the bell housing studs.

I suspect that the levers are poorly adjusted and are whacking into the clutch pedal cross shaft on full action.
The pragmatic engineer would get a set of 5/16 washers & slice them into a "C" shape. Then unbolt the gearbox retaining nuts, slide the C shaped washers between the gearbox and the crankcase and retighten. If the noise goes away you have identified the problem and implemented a solution that will last until you have a better reason to remove the engine.

Charles

Charles.

I recall the swearing involved helping dad do the very same thing to the RP now in the garage some 20years ago.

The washers are still there......

The C washers worked for me to adjust the throw of the mechanism and it's a lot easier than taking the engine out.