gearbox noise after replacing clutch

[alunian]

I have a 2000 UK turbo and about 3 or 4 weeks ago I had the clutch replaced and the fly wheel skimmed, when I got the car back the clutch pedal was extremely light that it felt more like a cable clutch which I could not feel the bite, also there was a lot of vibration that sounded like the engine was about to fall out when doing clutch control to park up or move very slowly.

I spoke to the mechanic and he said it should return back to normal within a few hundred miles. Over 200 miles later no difference.

I told him it should feel heavier than that and I have had clutches done in the past and never had this issue.

He asked me what to do, I suggested that I would contact a subaru specialist.
I spoke to Alyn at AS Performace about the clutch being light and the vibration and he stated he always changes the clutch fluid on all clutch jobs.

I got the mechanic to change the clutch fluid which he did for free and within 20 miles the clutch pedal returned to normal and the vibration is no where near as bad.

Now I have this Sh noise that sounds similar to brake pads rubbing when you rotate a wheel by hand coming from the gearbox but only in 4th gear when driving casually and lifting the clutch up slowly, but the noise goes away once the clutch pedal is fully engaged (up).

Any ideas?
Is the prop shift balanced and the mechanic has put it back in the wrong bolt holes as in it must go back in the exact rotation/bolts/holes as it came out?

Thanks in advanced

[alunian]

update.. I changed the gearbox oil last night and the noise went away for about 20 miles then came back

[alunian]

Spoke to Alyn at AS Performance this morning, he said it could be the shield that can cause issues when fitting the clutch as it can catch the clutch or something is loose under the car that is resonating. He doesn't think its the release bearing as it would be a constant noise.

I just find it odd that its only 4th gear that causes the noise.

[alunian]

I think I found the issue, you cant trust anyone these days.

The noise got so loud I was able to pin point the exact location of the noise and it was coming from both rear wheels, when looking through the rear wheels I noticed that the rear dust shields are missing, I know when I dropped the car off to have the clutch done that the dust shields were still there with only surface rust and were still solid. It looks like its been removed incorrectly leaving some remains rattling about.

Alyn is going to inspect it once I get it MOT'd, which could be a while since I need the sills done and there is a shortage of CO2 in my area for welding, shame you cant recycle the exhaust fumes lol.

[alunian]

Sills are done properly but we found 2 more issues before I can get a MOT.
1: there is a long crack at the rear of the chassis that almost reaches the mounting point for the subframe.
2: the inner metal at the rear needs replacing on the passenger side where the rear bumper is bolted to. These should be done in the next few weeks.
To Be Continued.

[alunian]

Nearly 1 year later, at least Im updating my thread lol.
The noise that was coming from the rear of the car is what is left of the rusty dust/back plates it was so rusty it had expanded and was grinding against the rear brake discs. My local garage discovered this when fitting new pads and discs, he had to take an angle grinder to get rid of must the rust.