Check clutch pedal freeplay!!!(general rule of thumb 1-1.5") As the clutch wears, free play increases sometimes causing the clutch not to fully disengage.


You only have the problem when down shifting? Do you feel a bump before the goes in all the way. The syncro's have "dog teeth" that need to cut between the oil, if it doesn't grind, then you have worn teeth or old tranny fluid which isn't moving around freely. Mostly, I knowtice the problem wit first and second when i am shifting at high rpm. A clutch that does not disenage fully would cause grinding sometimes but not always.