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[minivan69]

Hi all, putting it out there...

I'm trying to locate the source of a nasty knock that seems to be at drive shaft speed but only in 1st and reverse. No knocking at all in other gears...this has only started recently out of the blue.
Engine is near new and the gearbox, diff and clutch are new and only just run in.
Clunking is felt and seen through the Wand gear stick and sounds metal on metal shift into second and it disappears.

Does not seem to be cv joints as does it wether wheels are straight or turned. Drive shaft splines don't seem excessively worn and does not do it in other gears.

I have been to several mini experts with no luck. They say its not a typical mini problem sound and say it's not cv's

Driv'n me nutz...so much so I don't use 1st anymore and limit the need for reverse so not so practical?

Things I've done so far with no change...

1.
New poly bushes in engine support and added another support on radiator side in case engine movement was the prob.
2.
New ball joints and needle roller u-joints and also renewed drive coupling flanges themselves as they were slightly worn.
3.
Checked to make sure u-joints trun freely, not clamped too tight and not making contact with transmission housing and exhaust mount, exhaust down pipe.
Looked for scrapes etc nothing obvious.
4.
With front end off the ground, put in fist and reverse and no knocking so only happens under load and with suspension compressed

Knocking is worst when coasting down hill to the lights in first under load with clutch out. Does not do it with clutch disengaged or if in second.

Just did third oil change at 5k klm since rebuild to check for any signs of internal wear and found some metal filings found on magnetic oil drain plug.

Anyway, would appreciate any feedback as I'm lost.!!
Cheers.

Simon

69 van
Drums front and back
Dunlop Tasman 10" mags
1098 (rebuilt with 266 Kent, 1.5 hs4 pro rebuilt)
Magic wand gear change...obviously not working it's magic ;(
3 synchro (pro rebuilt box and diff)
Needle roller drive couplings
Hi-lo suspension/trumpets (set quite low...could this be an issue?)
Rubber cones good condition
New ball joints, steering rack, tie rod ends etc