D2 transfer case noise...

**davros** · 16th October 2009, 11:12 AM

Anyone know what this is...
At almost exactly 2200rpm my 2000 td5 d2 is making a "plinking" rattling sound that seems to resonate from the handbrake drum. It does not exist at other rpms as much (perhaps a little but definately not across the range; maybe at certain harmonics). At 2200 though it is loud enough to be heard very clearly with the windows down. It is lounder when the car is cold. It does not occur when parked or in "N", only when driving. If the handbrake is applied very slightly, the noise fades or even stops completely. Grasping the drum at the top and bottom with my finger wrapped around the backing plate, I can detect a fractional amount of movement in it (in perhaps an up-down direction but not in the side-to-side direction at all [although it is harder to get a good grip this way and the weight of the tailshaft is pulling down]) The amount is so small I'm not sure if this is normal play in the output bearing or not?
The uni joint (it's new, an attempt to fix the noise!), rubber coupling and slip joint seem fine and with a wheel off the ground everything seems to turn freely.
The tranfer case mounts flex easily when pushed "up" but they are not broken, maybe a tiny bit sagged.
If the car is held still with the foot brake whilst in "D" and revs taken to 2200 the noise is not present.
Oddometer reading is about 230,000
Any ideas appreciated!

Dave

Added: There is the usual intermediate shaft oil leak...

mike 90 RR · 16th October 2009, 11:23 AM

Not quite what your after ... but ....

A rattle ... (Marble in a tin can) sound from the mid area can also be a loose baffle plate in the center muffler
Also check the exhaust hanger bracket bolts are tight ...

Mike

**davros** · 16th October 2009, 11:39 AM

There was one rattle from the broken heat sheild on the left T case mount but I've dealt with that. There are also some exhaust issues but why would it not occur except when driving if this was the case? I have a feeling it's more mechanical (due to hanbrake application killing the noise), and it has that handbrake drum "ding" sound, not a tinny exhaust sound. However, would applying the brake also flex the drivetrain? My suspiscion is the output bearing or something in the handbrake drum. The handbrake cable has had to be adjusted to take up what appeared to be a lot of slack (but its not getting hot/dragging).

mike 90 RR · 16th October 2009, 12:20 PM

Originally Posted by davros

noise), and it has that handbrake drum "ding" sound

Sort of doubt the "output bearing" ... as usually they sound like a drive train noise ... Example would be a dull constant whirring noise .. (like a dead diff)

At certain revs, under certain loads, can give Rattles from a muffler ... It's all about "Harmonics" .... Not saying it is // Just part of the consideration

Crawl under the car, and start hitting suspect areas with a rubber mallet and see what might "Give itself away"

Mike

**davros** · 16th October 2009, 01:43 PM

Was wondering if some issue with the handbrake can result in the noise?
I am suspicious of the exhaust as the flex bellows are stuffed but that seems a different noise, it really sounds like a "dind aling aling" with the same pitch as the brake drum. So frustrating as I can't replicate it with the stationary car!
Does the trans case have adjustable load on the output bearing? Could something there be loose or out of spec?

**Litlbee** · 16th October 2009, 02:59 PM

Dont know wether it is the same thing but Ihad a similar rattle in my D2 TD5. Turned out it was the main nut on the rear output shaft. Only slightly loose but enough to make a noise. You need to remove the front flange from the brake housing to tighten it.
Regards,
Gary

mike 90 RR · 16th October 2009, 03:04 PM

Originally Posted by davros

.... it really sounds like a "dind aling aling" .....

I know the sound you mean ... The Hand brake setup is just like Drum brakes on a vintage car

Frustrating, I know ....
Chock the wheels, Hand brake off, gearbox in neutral, .... Keep hitting everything with the Rubber mallet

**davros** · 16th October 2009, 05:24 PM

Yeh it's really bell-like. Looks like the mallet will be put to use or I may just have to pull off the drum and have a look!
Also, in the copy of RAVE I have, it says there is an adjuster for the handbrake in the cab near the base of the handle once you pull the electric window switch panel off. I can only find the adjuster on the cable under the car. Am I missing something?

Dave

mike 90 RR · 16th October 2009, 05:52 PM

Originally Posted by davros

I can only find the adjuster on the cable under the car. Am I missing something?

Dave

Mmmm ... Forgot ... You've got the D2, so unsure on your handbrake adjuster
Earlier stuff has the adjuster on the back of the Drum ... metal backing plate has a square nut ... Wind clockwise (1/4 turns) to tighten (Dunno if you've got one)

Only getting you to hit areas such as TBox & exhaust, and any thing else you care to try.. to see if the Bell noise comes up ... Hoping to save you stripping & looking in the wrong places

The suggestion of a loose output shaft nut sounds good ....

Other solution is to trade der Disco in for a RRC .....

Mike

**Graeme** · 16th October 2009, 06:45 PM

Its an easy job to remove the drum and have a look, and cleanout all the dirt and dust at the same time.

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