zippydog · Mar 9, 2013

New on this forum. Just bought a 1986 ninety. Its had some mods done to it as you would expect. Its got a 200tdi engine and discovery gearbox. Its also got (i think) a discovery transfer box. How can i be sure what is in the landy even down to the axels (which have disc brakes). Is there a way of telling from serial numbers. I think the transfer box has different fluid in it depending on what its come from ( am i right).

I also have the usual transmission clunk when changing gear. I have just changed the rear half shafts which had obvious wear, but it has not got rid of all of it. Would the next logical thing be the "A" frame balljoint. I cannot see any obvious wear in it, but you can lever it up and down slightly. its difficult to get a metal bar in to check lateral movement cause of the brake pipes.

I guess because alot of the parts are donor parts from a discovery, you cannot say how many miles the running gear has done.

The last landy i owned was a lightwieght series 3 direct from the ministry. That was as tight as anything, admittedly the milage was low but it just felt good.

any advice would be appreciated. i guess this subject has been done to death, but it gets confusing reading all the threads on clunks.

cheers

Tom.JTC · Mar 9, 2013

Does transfer box still have the sticker/plate on it (look on the rear of it, below the filler plug) - if so it'll tell you the ratio which will tell you what box it is, 1.410 is the standard Defender ratio, if it's 1.2 then it's probably from a Discovery. Disco cases also need a mod to the handbrake bracket when fitted onto Defender so that may also be a clue - not sure on the details though.

You can also look here - scroll down to where it tells you to find the serial number, then scroll down further to find out what numbers relate to which ratios.

I believe all LT230 transfer boxes (at least pre-TD5) take EP90 or 80w90 gear oil.

A-frame is common clunk component, but so is everything else. Halfshafts a good start, did you also change drive members as they tend to wear more then the halfshafts themselves. UJs of course common to failing, can cause all sorts of odd clunks and squeals. I would check condition of gearbox mainshaft and input-gear, ones of this age (although having a disco box fitted the problem may have been rectified with a cross-drilled input gear) are common to wear due to lack of lubrication, splines eventually shear and your left with no drive - new gearbox. Lots of info on this site and Google on checking mainshaft wear.

zippydog · Mar 10, 2013

thanks tom. yes the sticker is still on there and it is 1.222 so thanks for the info.

I did change the flanges as well as the shafts and it cured alot of the clunk but not all. I will change the ball joint next because it's a cheap fix maybe not easy though, if it's still there I will move into the other things. the rear prop is ok cause I forgot to mention the prop was new not long ago.

thanks for all the info.

Seaswood · Mar 10, 2013

If I may ask with a transfer case # of 22D 04 688DC
Ashcroft reads; 1.4 & 1.211 or am I misreading 688 DC incorrectly?

Tom.JTC said:
Does transfer box still have the sticker/plate on it
(look on the rear of it, below the filler plug) - if so it'll tell you the ratio which will tell you what box it is, 1.410 is the standard Defender ratio, if it's 1.2 then it's probably from a Discovery. Disco cases also need a mod to the handbrake bracket when fitted onto Defender so that may also be a clue - not sure on the details though.

You can also look here - scroll down to where it tells you to find the serial number, then scroll down further to find out what numbers relate to which ratios.

I believe all LT230 transfer boxes (at least pre-TD5) take EP90 or 80w90 gear oil.

A-frame is common clunk component, but so is everything else. Halfshafts a good start, did you also change drive members as they tend to wear more then the halfshafts themselves. UJs of course common to failing, can cause all sorts of odd clunks and squeals. I would check condition of gearbox mainshaft and input-gear, ones of this age (although having a disco box fitted the problem may have been rectified with a cross-drilled input gear) are common to wear due to lack of lubrication, splines eventually shear and your left with no drive - new gearbox. Lots of info on this site and Google on checking mainshaft wear.

zippydog · Mar 18, 2013

Did the "A" frame balljoint which i bought off ebay as a complete unit including the "fulcrum" and the clunk has gone, sometimes just a bit of catch up on the drive. I guess the small bit thats left is down to the transmission wear for the age of the vehicle.
Thanks for the input.

zippydog

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Tom.JTC

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zippydog

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Seaswood

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zippydog

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