Transfer Gearbox Clang in Discovery II 1999 Manual V8

**LRT** · 22nd November 2010, 01:10 PM

When changing from low to high on the move but well under 8 km/h, there is a clunk that turns into a mighty clang after moving the transfer lever from neutral into the high position. The clang sounds whilst the clutch pedal is depressed. When the clutch pedal is released, the Discovery drives normally in high range. What is the likely cause of the clunk and clang, which seems to come from the transfer-box? The uni-joints from the front axle to the transfer-box are in good condition. However, there is noticeable slack at the transfer-box flange when the front propellor shaft is removed. LRT

**Scouse** · 22nd November 2010, 01:23 PM

The transfer case is like an old crash box - the gears aren't in constant mesh so the sound is just the gears engaging.

The slack in the front flange could just be a bit of freeplay in the centre differential.

**LRT** · 22nd November 2010, 01:59 PM

Thanks Scouse for your comments. The puzzling thing is that, in our Defender 130, which has done 280,000 k's, there is only a slight clunk when we change from low to high, even when we change at much higher road speeds than in the Discovery. Nor is there a clang sound in the Defender. The Discovery, which has done 100,000 k's less than the Defender, has done little low transfer work - at least as far as we were led to believe when we bought it!! LRT

**Scouse** · 22nd November 2010, 08:13 PM

Sorry, I didn't realise you'd had LRs before.

Maybe the D2 High/Low selector is a bit stiff & it doesn't slide/enagage as smoothly as the Defender one.

**LRT** · 23rd November 2010, 08:09 AM

Many thanks Scott for thinking more about my question. It would be a great relief if it is just a stiff selector, especially as Mum thinks we may have bought an expensive road-friendly family 4x4 wagon that should have been painted lemon rather than Epsom green! Caleb

**ozscott** · 23rd November 2010, 02:26 PM

They can be a pain at times mate. You have to double shuffle - the user manual has a good write up on it. Cheers

**BigJon** · 23rd November 2010, 06:10 PM

If you can't get it to change without clanging, stop to change ratios. It is just a dog box, you need to have the speeds of the gears right for them to engage smoothly.

**LRT** · 23rd November 2010, 08:05 PM

Yes BigJon, I will need to stop to change from Low to High ratios. It does seem that I need to be more familiar with the overall gear ratios of the D2. What disturbs me is that I can progressively shift from Low to High range in our Defender 130 and our old Series III so that I have eight progressive forward gears with smooth changes without clunks and clangs.

**LRT** · 23rd November 2010, 08:19 PM

Thanks ozscott. The user manual is indeed a good guide on the advanced method of using the D2 manual gearbox and transmission. You are spot on about the need to double clutch, which I have learnt to do smoothly on a Series III so that I can use eight progressive gears when towing heavy loads. It is disappointing that this technique doesn't work well on the D2, which makes me think something is mechanically amiss.

**biggin** · 23rd November 2010, 08:20 PM

Originally Posted by LRT

Yes BigJon, I will need to stop to change from Low to High ratios. It does seem that I need to be more familiar with the overall gear ratios of the D2. What disturbs me is that I can progressively shift from Low to High range in our Defender 130 and our old Series III so that I have eight progressive forward gears with smooth changes without clunks and clangs.

I have the same clunking in my 2002 with 128,000km on the clock. I'm sure it's nothing to worry about though. As BigJon suggests, I always stop to change up and down.

Thread: Transfer Gearbox Clang in Discovery II 1999 Manual V8

Thread Tools