discovery clunk

[tyler]

Hi
I was recommended to this site and hope you guys can help us.
We are in search of a diagram of the transfer box of a discovery series 1. 1995 model tdi 5speed about 198 thousand.kms. Everything else is great we have overhauled the motor however we now have a clunk. Perhaps someone can help?
We have a HAYES book however it is not in there.
There is a clunk when we accelerate, it cannot really be felt just heard and happens at accerlation at any speed. If cruising for a while then accelerating it can also be heard. Any ideas. I have recieved some advice from a general forum however it was suggested that we ask you guys as you are the landrover people!
Thanks in advance
Lenni

[one_iota]

Welcome Lenni,

This site has the complete workshop manual on CD (RAVE) for the modest price of $15.00 (+GST). Worth getting.

http://www.aulro.com/modules.php?name=Shop...ewprod&prodID=6 (http://www.aulro.com/modules.php?name=Shopping_Cart&file=product&c_op=viewprod&prodID=6)


But.....have you checked the ball joint on the A-frame?

http://www.aulro.com/albums/album26/aframe.jpg

[disco95]

Here's what you were after, but as one iota suggested, the rear ball joint is the first place I'd be looking.

http://www.aulro.com/albums/album197/Scan2_001.sized.jpg

[tyler]

Thankyou for the information and the diagram we will let you know how we go with it! We will check out the ball joint first.
If you think of any other suggestions please let us know.

Regards Lenni

[sclarke]

My money is the output shaft on the Gearbox is worn and the input gear on the Transfer is worn.

Easy to check.
pull the PTO plate off the Transfer (6 bolts) and pull the gear out. The internal splines are the ones that wear.

Good luck

[camel_landy]

It's quite common on the Disco for the gearbox output shaft splines to wear. The splines on the rear half shafts (axles to you guys) are another place to look. If not there, have a look at replacing the bushes.

The A frame joint can wear but in my experience I'd stick it way down the list of places to look.

HTH

Mark.

[DEFENDERZOOK]

Originally posted by camel_landy
It's quite common on the Disco for the gearbox output shaft splines to wear. The splines on the rear half shafts (axles to you guys) are another place to look. If not there, have a look at replacing the bushes.

The A frame joint can wear but in my experience I'd stick it way down the list of places to look.

HTH

Mark.


<span style="color:blue">i was thinking half shafts too....but stayed silent......
as far as i know....you can feel the clunk from the half shafts as the slack
is taken up under drive or overdrive........

everyone seems to have avoided the simple stuff.....
as tyler is suspecting transfer case......simple dry half shafts wear the splines
and have freeplay enough to clunk.....

mine lasted only 60,000kms and were replaced......

there are other things it could be as well....such as loose radius arm bushes....etc...


tyler...dont go pulling the transfer case appart just yet....
it might not be the problem....check the other stuff mentioned first till you
are sure what is making the noise.....</span>

[sclarke]

ok guys i jumped the Gun............. story of my life.....

Sorry love that was my best effort to date..... 34 sec... :roll:

[DEFENDERZOOK]

<span style="color:blue">its just a matter of finding the definite problem.....

not just assuming the mechanic they took it to knew what the problem was....

clunks are tricky to diagnose over the net using someone elses ears....
and descriptions....

im discounting the transfer or the box.....just checking the simpler options first.....
everyones advice will help.......</span>