Wonder if the STW massive can help with this. On a 12 year old Peugeot Expert (Mk II) pressing the clutch pedal, the pedal seems to hit a stop but gears grind when changing, especially up or down into 2nd. But the stop is artificial, a bit more pressure and the pedal drops another 1 or 2 inches and gear change is much smoother. Seems to require less pressure to pass the fake stop in higher gears. Stop point is consistent and pressure required is always the same no matter how the engine is revving
Feels like a pedal issue more than the clutch/gearbox itself
EDIT cables not hydraulic
Any ideas?
TIA

Frayed cable? ‘Stop’ being where a frayed bit hits the sleeve and needs an extra push to bend out of the way / slide in.

Yeah sounds like linkage or hydraulic issue. Any noises.. Other than the gears grinding?

Cable replaced about 8 months 30k miles ago
Will have a look around the sleeve for frayed cable anyway – got the Haynes manual so should be able to find it
No noises apart from grinding and then only if pedal not pressed beyond fake stop

Cheers

Fake stop could also be a mechanical issue with the Pedal.

I’d disconnect the cable at whichever end is easiest and check the Pedal moves correctly.

Put your foot behind the pedal & push it up to ensure its starting at the top of it’s stroke again. I used to drive a 406 taxi that developed a similar problem , doesn’t sound quite the same as yours but its worth a go. Never found out why it did it & just got into the habit of tapping it back up with my toe.

Self adjusting ratchet could be shot….

Or the pressure plate is on its way out

Yes…. 12 years old…. hope it’s not the actuating arm rocker bearing about to burst through.

It’s a clutch/pedal thing not related to speed (engine or vehicle) with no worrying noises other than changing gear with pedal not depressed so can’t see it being anything to do with the rocker arm

Yeah those are words he made up.

He means the clutch fork

The nose of the clutch slave can punch through the clutch fork

When this happens the clutch doesn’t fully disengage no matter how hard you push the pedal.

Not familiar with van but can you not disconnected cable at gearbox end and pull the lever by hand and see if it still feels as described and if so looks like you will need to take gearbox out