Hi
I bought a 1991 defender pickup off the bay last year and I am in need of some advice with the noises I can here.
All prop shafts have new uj's which reduced the clunk and squeals, when I changed the t/box oil I got about 4more pints than expected.... and the gearbox oil was changed from ep80 to ATF.
Following this I can change gear much better but now I have several problems.
1. Still struggle to get into 2nd
2. Clunk when I let the clutch out on 1st and 2nd
3. Metallic screeching/grinding sound in 4th and very bad in 5th
4. When I ease of the accelerator there is a grating/rubbing noise in all gears but especially 3rd

Last weekend I put some molyslip in to the gearbox and it is much better in 4 and 5th but do I need a recon box and transfer box? Is it worth getting the clutch done whist its all out? Should I go for a disco t/box so its a more relaxed drive?
Any help appreciated.
Thanks
Paul

Has your A frame ball joint been replaced recently? This is a common cause of a clunk. My clunk turned out to be the worn output shaft splines of the gearbox into the transfer box

Defenders all clunk, but if it's especially bad as said above remove the PTO cover and check the splines on the gearbox output shaft, they wear on early Defenders. If they are worn it's new or recon gearbox time.

And yes do the clutch whilst it's all apart.

Finding 4 pints more than expected in the transfer box is usually caused by an idiot filling from the wrong hole. I made a total mess of my garage floor a few months ago when a mate came over with a leaking transfer case. I couldn't find any damaged seals so I thought I'd top up with oil and see what happens. When I opened the filler / level plug behind the hand brake drum, a huge quantity of oil gushed out and it took forever and a day to clean the mess up.

Hi
Thanks for the replies. I have not had the a-frame bush done and I will check the input shaft when I get chance. Is their any other way of checking what is worn?
Thanks
Paul