Peugeot 206 NEW clutch pressure and clutch plates were replaced including the bearing. Clutch is making a rattling noise but not when pedal is down. Having difficulty getting into 1st and 2nd gears. Mechanic can't figure out why it is making a noise, what could it be?

most clutch kits do not include a new throw out bearing as that is bought separately
most likely that the mechanic doing the job thought that if the bearing was included (around $25.0 aud) that he would not get the job or he ripped you off by not putting the new bearing in
could be the bearing as they do work hard and are mass produced and are known to fail early
a faulty bearing is shown by a tinny rattle when the clutch is engaged or a growl when the clutch is disengaged
if the noise goes when the clutch pedal is pressed slightly , it indicates that the bearing is rattling on the pressure plate fingers and there is a need to adjust the freeplay at he slave cylinder
.it is not necessarily a faulty bearing

Try starting it in gear than shift with rpm dwn shift Rev rpm up by 1500 to up shif let rpm go down by 1500

opel vectra ,,,,ot sure if their is a automatic adjustment on the pedal ,if so it could be this failing which the cable could be frayed ,would really need to see it to know for sure

It could be a loose/failed engine or transmission mount. Look at the tranny rear mount and check the bolts and condition. Also check the bell housing bolts AND the bolts connecting the engine flywheel to the clutch pressure plate.

should be a spring holding it taught till you press the clutch

The reason for the high biting point is simple. The clutch is made of 3 main components.
The pressure plate friction plate and the release bearing.
The more times clutch is depressed the concentric spring fingers wear in 2 ways . Firstly by good old metal to metal rubbing and secondly the concentric spring fingers don't return as far as a new one causing the release bearing or csc to adjust .
When the pressure plate concentric spring gingers wear they don't sit proud and require more pedal effort to depress. .
When they loose there spring like feature they require a greater distance from the release bearing. Or it has to travel further to depress them to lift The pressure plate and fee the friction plate from the lay shaft on which it is splined onto to give you drive once released.
The further back the bearing has to travel to allow the fingers to clamp the pressure plate to the friction plate . The more the clutch has become worn and unserviceable.
Self adjustment on hydraulic clutches are a hard one to gauge as you have no idea how far the piston has moved out to compensate for this wear . With a cable you can physically see the wear and adjust .
High biting points on any car are useless. You want a biting point to be 2 to 3 inches from the top and not nearly level with the brake pedal.
Anyway it seems apparent that Peugeot and Citroen both have high to almost no point at which they bite .
I myself would modify this as an engineer.
But it seems to be normal on these cats to have absolutely no biting point worth talking about.
My sisters 2012 206 1.4 is a very high biting point and I myself would not be happy with it . It gives u no indication of a worn clutch if its self adjusting.
Alll hydraulic clutches are self adjusting. So why are Peugeot and Citroens sooo high. Its ridiculous.
A very idiotic idea and I'm taking it back with her and I'm complaining. Hopefully I should get somewhere and ill update you all

Hello, Who installed the clutch"? Were there a new pressure plate installed? Were there a new throw out bearing installed. Does this 1991 Peugeot 405 have hydraulic or mechanical clutch linkage?
There a couple of reason why the Peugeot wont move and engine is running and the transmission is in gear.

1.. Pressure plate is installed backwards.--Remove transmission and reinstall pressure plate in the correct orientation to the clutch. There is two ways to install it, but one way correctly.

2. Adjustment for the clutch linkage from the pedal in the driver compartment is adjusted to tight and not releasing the clutch to where the clutch pressure is on the pressure plate.



I hope this helps. GB....stewbison

A rattling noise from the transmission is never a normal condition no matter what anyone says, and the first thing to do is to check the transmission fluid level, but it sounds to me like the throw-out/release bearing is riding the clutch pressure plate, and when the clutch pedal is in the up position the throw-out/release bearing and the clutch pressure plate should not be touching each other, and the only time that they should make contact is to release the clutch disk in order to shift the transmission into gear. There should be about 1 to 2 inches of free play in the clutch pedal, and the clutch should start to grab within 1 to 2 inches of letting the clutch pedal up off of the floor, and if this is not the case you might need to have the clutch properly adjusted especially if the clutch does not start to grab until the clutch pedal is half way up from the floor. Also, the main bearing in the transmission could be going out due to low fluid, or a damaged pilot bearing that is allowing the transmission input shaft to wobble just enough to cause a rattle from the main bearing or even a vibration in the transmission.

It seems like the clutch pressure plate has given in. Best would be to replace the clutch pro-kit.( Clutch pressure plate, clutch plate and release bearing)

It seems like the clutch pressure plate has gone, not releasing the clutch plate once the pedal is operated.
The noise you hear, is it a screeching one or is it like the gears rubbing eachother.
If its a screeching noise thn its the release bearing and if its a heavier grinding noise thn its the gears.
Guess you will have to replace the clutch pressure plate, its highly recomended though to replace the pro-kit,i.e the clutch plate, pressure plate and the release bearing.
Good luck.