Clunking noise on my 2003 Def 90 TD5

JAD90 · Nov 5, 2016

Hi all

Ive got a clunking noise when in 1,2,3,4 gears. sort of a fast nocking when setting off and driving from the gearbox area
noise not heard whilst in idle or when clutch is down whilst moving.
not heard when the diff lock is on in H or L just crawling along.

I had a quick play with the shafts today, rear one is solid with handbrake on, no movement at all..
when handbrake is off, both front and back turn slightly, but since its been awhile since I've had a Defender can't tell whats normal play and whats a knackered UV joint.

Sorry for the usual... "my defender is making a knocking noise thread".

thats the best description I can come up with.

Its a 2003 Defnder 90 TD5.
stock, not lifted etc.

Thanks for the help

mikescuba · Nov 5, 2016

Have you checked the ball joint on the A frame at back? When the joint is worn you get a clunk as you apply the power.

JAD90 · Nov 5, 2016

would that make a repetitive "clunk,clunk,clunk,clunk,clunk... noise when setting off and driving?

tottot · Nov 5, 2016

Not A frame joint,sounds like a UJ problem, if you can not feel any play in a joint it may be that one journal has seized/partially seized.After a run check joints for a hot one [careful] front transfer output is likely culprit at it's the one that moves the most.

JAD90 · Nov 5, 2016

Tottot that sounds about right.. there prop turns a little each way as to be expected but the joints don't wobble at all which is what i would expect they should do, even a few mil

Ill take the front prop off and take a look and possibly drive it a little without it on to see if that gets rid of the clunking, just to see if it is hopfully not a noise from the gear box.

Ill just make it a rear drive defender for an hour

JAD90 · Nov 5, 2016

Just taken the front prop off.. all the joints feel fine. drove it down the road and its still making the knocking noise.. Ive recorded the sound which i will upload here for any experienced ears.

JAD90 · Nov 5, 2016

try this audio link for the strange noise

let me know if it doesn't work.. noise is more noticeable half way through

tottot · Nov 5, 2016

Check the rear shaft next,easy things first.What speed were you doing while recording.

JAD90 · Nov 7, 2016

I had just set off so not going very fast at all. Ill take a look at the back shaft today. going to drain the gearbox oil also and refill.

Since its been sat for sometime when i took the tray off, it was a bit oily, so maybe not enough oil also?

JAD90 · Nov 12, 2016

so I think its the transfer box, dropped the oil and very metallic and lots stuck to magnet, with a little chunk of something 1mmx2mm maybe.

so I think there is a tooth or two missing in the transfer box, now need to figure out if i can drop it on the drive or need a lift ?

boguing · Nov 12, 2016

I have lowered them onto a sheet of hardboard (shiny side down) and slid them out without lifting the car, although I never did check to see what springs that car had. You may need to lift it an inch or two with old springs. You need to take out the crossmember under the gearbox, tunnel, floor panels and seat panels.

frog hopper · Nov 13, 2016

A good tip someone else posted ages ago for refitting was to get 3 long bolts cut the heads off and hand screw them into the gearbox to guide the tranny box back on. Made a real difference to me as once it was on the guides I could have a breather before sliding the whole lot together, helps to keep the oil seal aligned as well.

Clunking noise on my 2003 Def 90 TD5

JAD90

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mikescuba

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JAD90

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tottot

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JAD90

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JAD90

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JAD90

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tottot

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JAD90

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JAD90

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boguing

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