ivancrx · May 26, 2015

Hi all.

I have a 1990 defender which has had a 200tdi disco engine put in it, For the past 2-3 months I have been doing a little work on it, new refurbished rear diff, striped the rear 2/3rds of the chassis and removed all the suspension at the rear and replaced etc. etc.

Today I have taken it out for it's first small journey and it sounds like a bag of nails, it almost sounds like it has a misfire but there is no lack of power. The only bit of the engine I have touched is put in a new clutch and fit a new power steering and alt belt. The gears change perfect and there is no noise from the gearbox area.

Oil is spot on the upper level, what could have gone wrong when it wasn't being used?

Any help gratefully appreciated.

Cheers

Ivan

Marmaduke · May 26, 2015

What's it like when ticking over or fast idle as opposed to driving it?

ivancrx · May 26, 2015

Marmaduke said:
What's it like when ticking over or fast idle as opposed to driving it?

No noise at tick over or at low revs driving just anything over 30mph in 4th and it starts rattling.

Marmaduke · May 26, 2015

Is it only when 4th and above 30? What about 3rd and 30 or free wheeling and 40?

Dippypud · May 26, 2015

Rocker shaft ? Check the valve clearances as a first step ...

Might even be dodgy injectors ...

UJs

Southernlandy · May 26, 2015

Worn propshaft uj's?

Turboman · May 26, 2015

ivancrx said:
Hi all.

I have a 1990 defender which has had a 200tdi disco engine put in it, For the past 2-3 months I have been doing a little work on it, new refurbished rear diff, striped the rear 2/3rds of the chassis and removed all the suspension at the rear and replaced etc. etc.

Today I have taken it out for it's first small journey and it sounds like a bag of nails, it almost sounds like it has a misfire but there is no lack of power. The only bit of the engine I have touched is put in a new clutch and fit a new power steering and alt belt. The gears change perfect and there is no noise from the gearbox area.

Oil is spot on the upper level, what could have gone wrong when it wasn't being used?

Any help gratefully appreciated.

Cheers

Ivan

Check tappets fuel filter etc first. Has the timing belt slipped or jumped a tooth?

Get underneath and pull the propshafts around, check for loose bits etc.

ivancrx · May 26, 2015

Marmaduke said:
Is it only when 4th and above 30? What about 3rd and 30 or free wheeling and 40?

Sorry 4th at 30 was an example of the revs it can be heard at, but it is through all gears, no noise at all when freewheeling.

All the UJ's are fine I have checked those and there is no play in them.

It does sound like a very loud tappet noise, but there wasn't a problem before I started the work, could it be a sticking tappet?

Turboman · May 26, 2015

ivancrx said:
It does sound like a very loud tappet noise, but there wasn't a problem before I started the work, could it be a sticking tappet?

Always worth a tappet check on an old diesel anyway

Wind the engine round clockwise, use the rule of nine, go through them all, sticking/broken rockers or valves should be pretty obvious.

ivancrx · May 26, 2015

Turboman said:
Always worth a tappet check on an old diesel anyway

Wind the engine round clockwise, use the rule of nine, go through them all, sticking/broken rockers or valves should be pretty obvious.

Rocker off tomorrow, or is it off my rocker tomorrow.

Loads to go at then, I will let you know how I get on.

Many thanks

Brown · May 26, 2015

An experience I had 30 years ago after changing the clutch on a Vauxhall Viva comes to mind. We put the gearbox back on and it was a bit reluctant to mate up but my friend who'd done it before seemed to think it would be OK to wind it back together by tightening the bolts. When under power there was a clattery noise that sounded very tappety at about the same frequency as the engine revs. It turned out what had happened is the bronze bush in the end of the crankshaft that the gearbox input shaft goes into had got rucked up as the engine and gearbox went back together, which was why it was a bit stiff to mate up.

Couldn't be anything similar at fault on yours by any chance?

ivancrx · May 27, 2015

Brown said:
bronze bush in the end of the crankshaft that the gearbox input shaft goes into had got rucked up as the engine and gearbox went back together

Couldn't be anything similar at fault on yours by any chance?

Oh please I hope not.

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