Hi all,

So a while back I posted about an issue with my 5 speed manual. After slowing down, changing down, braking and going round a slow 90° bend, upon moving back to accelerate (normal driving) I used to get a single knock. I couldn't find anything loose and neither could the garage. Replaced ball joints, both axles, drop links and still persisted. So I decided to go 6 speed conversion because I put it down to gearbox issue, although I done the wishbone bushes and arb bushes at the same time.

So bought a full conversion from breaker. The DMF with it seemed OK and after speaking to LUK it was well within tolerance (almost new, and looked it) first start it rattled, but dip of the clutch and let up it seemed to centre the flywheel and then no noise. However the gears always seemed a bit notchy and clunky (more so first and second) but lived with it. Recently the flywheel seems a touch more noisy, but still quiet compared to my old diesel car flywheel. Now im noticing that the gearbox seems to almost lock in gear under engine breaking, really hard to pull it out of gear without a clunk, and most gears now seem on and off notchy. Gear oil is new redline MTL and cables are loose etc, slave is new and bled properly. Is this a gearbox issue?

I'm not sure really because of the amount of work involved and money;

Risk original 5 speed I still have
Replace DMF with OE
Replace with solid
Find a lightened flywheel probably better suited to a mini one.
Leave and fix when I find all the pieces on the road behind me.

Any ideas as I don't want to fit a flywheel and find gearbox is cankered or fit 5 speed and find it was faulty. 6 speeds in the UK seem to have climbed in price :/

Cheers