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Just thought I'd update this.

Just thought I'd update this.

We ordered a new clutch plate and diaphragm, heavy duty clutch arm and associated consumables.

On reassembly I noticed the primary gear wasn't spinning as freely on the idler gears as it should, not sure how we missed that, probably too focused on the clutch/ flywheel side of things... Now we checked the end float before reassembly, and had used a 'grey' transfer case gasket from the kit. I can only assume that once torqued the gasket crushed far more than usual and I've overlooked it . Swapped the gasket out for a genuine Rover one and that problem was solved.

Put it all back together, and once again the carb gaskets (from the kit) were too thin, so the linkage hit the inlet manifold. So had to wait for an order from Burlen, their gaskets being 1.5mm thick.

Any way, all reassembled and running properly again!

Thanks again for all the help!

Ah, so the Idler Gear ended up being pinched.

Good find.

That was pretty astute picking that up Olly. All caused by the thickness of a gasket nipping the primary gear........