Cyclic rumble in first and second gear

[Brid]

My 2007 Puma has must developed a cyclic rumble driving in first, second and reverse. Add least that's when I hear it easily. Stationary with transfer in neutral it sounds like the transfer case, which I overhauled when upgrading about 40,000km ago. The magnetic plug had only a light paste, and oil clean.
Could it be referred noise from the clutch, although it feels fine. I'll probably take the inspection plate off the transfer for a look.
Does anyone have any ideas please?

[Brid]

So vehicle stationary, transfer in neutral and going through the gears, the noise is there in every gear. Just gets fast going to a higher gear. That obviously rules out diffs, U-joints, and all the transfer case except the input shaft assy...at least as far as I can see that would be the case.

The oil is very clean, and no metal flake on the plug.

Apart from the input shaft, is it possible that a clutch issue, or gearbox, or gearbox extension shaft (which was replaced with the Ashcroft fix) could refer noise to the transfer? Probably more play in transfer than gearbox. Maybe someone more experienced than me might have some ideas?

[Brid]

Can anybody recommend a good Land Rover mechanic on Brisbane west side?

[incisor]

Don't know of any in the western suburbs. I had diff rebuilt by a mob at Everton Park and whilst there they diagnosed a gearbox problem that I couldn't hear so I was suitably impressed with their diagnostic skills... Dantrans was the name if I remember correctly... They were on queens rd

[Brid]

Thanks for that referral, Incisor.
I spoke with DanTrans, and having relayed the above information, they said it would almost certainly be a clutch issue. If the transfer case noise is only present at low revs, and seems fine at higher speeds, it's not the gearbox or transfer case. Transmission noise would only get worse. It's very common for clutch issues to refer the noise to transmissions.
I was at a stalemate not wanting to pull the transfer case apart again when it looked good, and not wanting to replace the clutch without being sure.
Cheers
Brid

[carpdvl]

So vehicle stationary, transfer in neutral and going through the gears, the noise is there in every gear. Just gets fast going to a higher gear. That obviously rules out diffs, U-joints, and all the transfer case except the input shaft assy...at least as far as I can see that would be the case.

The oil is very clean, and no metal flake on the plug.

Apart from the input shaft, is it possible that a clutch issue, or gearbox, or gearbox extension shaft (which was replaced with the Ashcroft fix) could refer noise to the transfer? Probably more play in transfer than gearbox. Maybe someone more experienced than me might have some ideas?Is it a constantly increasing noise as you increase road speed or changes with engine speed as you change into each gear but more intense at higher speeds (like it restarts in each new gear)?

If it is constantly increasing that mostly rules out input shaft on gearbox because that will change with engine speed. That leaves you with as you said your output shaft in the gearbox, adaptor and input into TC and, importantly, also your intermediate shaft in the TC. When you are spinning through the gears with the TC in neutral only the output shaft is stationary.

I just had a bearing going on my intermediate shaft a year and 5000km after rebuild. It made a whining noise that increased with road speed and was much more intense in low range.

If you can, drop the TC out and then try rev it through the gears - that will isolate it to gearbox or TC end, and you can go from there.

[carpdvl]

Thanks for that referral, Incisor.
I spoke with DanTrans, and having relayed the above information, they said it would almost certainly be a clutch issue. If the transfer case noise is only present at low revs, and seems fine at higher speeds, it's not the gearbox or transfer case. Transmission noise would only get worse. It's very common for clutch issues to refer the noise to transmissions.
I was at a stalemate not wanting to pull the transfer case apart again when it looked good, and not wanting to replace the clutch without being sure.
Cheers
BridOh as an aside, I also did clutch while in there - similar-ish symptoms, a rattly rumble that wasn't present so much in neutral revving. Similar puma 2.4, the early ones had rubbish springs so sounds like you may have found your culprit.

Put a decent clutch in with good springs - I went with LOF which are gaining popularity.

[goingbush]

Is it a constantly increasing noise as you increase road speed or changes with engine speed as you change into each gear but more intense at higher speeds (like it restarts in each new gear)?

If it is constantly increasing that mostly rules out input shaft on gearbox because that will change with engine speed. That leaves you with as you said your output shaft in the gearbox, adaptor and input into TC and, importantly, also your intermediate shaft in the TC. When you are spinning through the gears with the TC in neutral only the output shaft is stationary.

I just had a bearing going on my intermediate shaft a year and 5000km after rebuild. It made a whining noise that increased with road speed and was much more intense in low range.

If you can, drop the TC out and then try rev it through the gears - that will isolate it to gearbox or TC end, and you can go from there.

You would not need to drop TC, just pull the intermediate shaft.

I don't understand how a clutch could make a cyclic noise , or any noise if it engaging properly.
a little pressure on the clutch h pedal should eliminate any throwout bearing noise & you should feel a crook bearing through the pedal.
A faulty DMF I could understand, but I thought Pumas had a solid flywheel.

[Brid]

Sorry for delay in response, and thanks for comments. Oil back in transfer and time for more testing. Noise cycles increase with road speed. Tfer in neutral increased with engine from and higher gear.
Today I was able to hear cycling the first time, cycling noise with main box in neutral.
Put clutch in and noise gone. Still there with pressure on clutch pedal, but gone when disengaged.
Would that narrow it down to clutch or main box input?

[Brid]

Sorry...I should have followed up with the result earlier.

Although it was driveable, I tilt trayed it to DanTrans, just in case it wasn't the clutch. Lucky I did...it turned out to be the input bearing, but also the input shaft had excessive wear, and also some wear on 5th/6th gear. An overhaul was the same cost as a new gearbox, so I went for the latter. (MR Automotive usually stock them.) Big cost! But I'm keeping it long term.

DanTrans said I was very lucky to get 340,000kms from it, as usually they fail before 200,000km!! Plenty in the Rangers fail early, and some extremely early he told me.

[Juff]

Thanks for all the info, I’m getting some noise in 1st and 2nd, already got the Ashcroft output shaft and new clutch so thinking bearing in the gear box [emoji853]
I heard an exchange box was around $2000 (plus fitting). Does that sound about right?
Thanks
J