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Thread: Gearbox rattle and limp-home mode

  1. #1
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    Gearbox rattle and limp-home mode

    Hey all,
    Our 2003 D2a TD5 has developed a tinny rattle under certain revs that starts as soon as the ignition goes on, so is obviously something electrical. Sounds a bit like two strips of metal vibrating together. Gear shifts have suddenly become a bit harsh, slamming rather than slurring, and today SWMBO said after a short distance the Disco kicked into limp-home mode with the engine warning light, and the M and S warning lamps lit up. Stopping the vehicle and restarting the engine cleared the warnings, but the rattle is still there. We were having problems with the inhibitor switch (again) before this, so I'm not sure if this is the next stage in its long, slow death.
    Any insight?
    - sanbar

  2. #2
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    Would a catastrophic catalytic converter failure have something to do with this? It's the exhaust rattling up near the engine, not the gearbox.

  3. #3
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    gearbox rattle

    You haven`t got a cracked flex plate have you?

    Trev.

  4. #4
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    Inspection

    Remove the inspection cover on bellhousing and look at the
    flex plate triangular shaped thing three bolts on tips look
    for fractures or damage all over.
    You need to turn engine by hand to get a good look.

    Pete

  5. #5
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    Clearly completely unrelated to your gearbox issues, but I just found a tinny rattle that had plagued us for 18 months. It was the washer on the bolt that holds the gearstick shaft in place onto the stick coming out of the box. Only noticed it as i was test driving with all the centre console removed and could source the rattle direct.

  6. #6
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    Quote Originally Posted by sanbar View Post
    ... starts as soon as the ignition goes on, so is obviously something electrical...
    Do you hear the sound after you turn the key but before you crank and start the engine, or is it only after it's running?
    Regards, Will

    Stornoway Grey '09 D3 TDV6 SE, 2015 TERRITORY Engine at 348k
    LLAMS, FYRLYTS, OL D4 Bar
    Safari Snorkel, D4 hitch, ARB CKMA12

  7. #7
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    With ignition on, but before the engine cranks.

    Quote Originally Posted by winaje View Post
    Do you hear the sound after you turn the key but before you crank and start the engine, or is it only after it's running?

  8. #8
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    Thanks for the reply. If you hear exactly the same noise with the ignition on both before and after you crank and start, then that noise is not caused by anything motor driven in the driveline such as the flexplate cracking (although it's worth checking that anyway). I'd suggest disconnecting, thoroughly cleaning and reconnecting all the electrical connectors that service the transmission.
    Regards, Will

    Stornoway Grey '09 D3 TDV6 SE, 2015 TERRITORY Engine at 348k
    LLAMS, FYRLYTS, OL D4 Bar
    Safari Snorkel, D4 hitch, ARB CKMA12

  9. #9
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    The rattly noise, with ign but not running, is possibly the little fan that samples the air temp. On the RHS on the steering column, you'll see a small grille. this wole width panel (about 2-3inches) pulls out. Clean the fan and take it apart and apply a SMALL amount of grease to the blade bush.

    The rattle with engine running, is it tinny, like someone tapping the edge of a piece of plate steel? Probably the flex plate, common issue. Unless you can find a known good second hand one locally (and even then for < $100-) get one sent from Ashcrofts. Mine was about $50- incl shipping (was with other stuff as well). New local was over $600- and had to come from UK anyway, which from rover is a week or 2, Ashcrofts 2-3 days door to door.

  10. #10
    Tombie Guest
    Long shot... But they tie together...

    How old is your battery?

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