Clunk on driveline

hi guys
I have a problem with my defender 300tdi ,it had a bad clunk on taking up drive and a bad oil leak on transfer box ,it's been into a local garage and had transfer box out and seals replaced and also 4 new u/j s
Fitted.the mechanic said that bearings in transfer box looked all ok and that the clunk was caused by the badly worn rear prop u/j.
I've now got the defender back and the clunk is still there,there is also another bad clunk now when changing down gear into 3rd from 4th,I can actually feel it through gear lever as I release clutch.this didn't happen before garage had it.
It's also STILL leaking oil from transfer box despite new seals been fitted
Any ideas what could be causing the clunk that I can check next? I can't afford to take it to a garage again for them not to cure it

Hi ,

Have you checked the A frame ball joint? Mine clunks, I checked it the other day and I can feel the balljoint is loose. This shows how mine was loose ( first video)
https://www.landyzone.co.uk/land-rover/it-never-ends-damn-you-90.313396/

Cheers

Sorry to hear your story. It's really frustrating when you spend your hard earned cash and don't get a positive result.

IT's out of my field of experience. I have had a number of odd clunks but they were prop shaft related, easily fixed and cheep.

Good luck. I'm certain that someone here will have an answer for you soon.

I will check the A frame,thanks for that.
I'm so disappointed ,spent a lot of money and all I really have to show for it is 4 new u/j s ,I still have the clunk and still have an oil leak from transfer box and if I'm honest the whole thing sounds much more noisy now somehow ,especially in 3rd and 4th gear

What did the garage say about the fault not being fixed?

Cheers

neilly said:

What did the garage say about the fault not being fixed?

Cheers

Click to expand...

I've only picked up the truck at 5pm today,I've only noticed it still has a leak once it was sat on my drive for 10mins and I've only noticed the problems with the clunk when I took it for a good run.the garage is only 1/2 mile from my house and it never got out of 2nd gear on way home in traffic so I've not told them yet

I'm going to ring the garage in the morning and tell them the problems I've still got.thhe problem is I've now lost all confidence in them and don't really want them doing anything else to my defender,it actually seems worse now than when I took it to them,I've just been out for another drive in it and it's so noisy in 3rd and 4th gear.i can't understand how it can be when they've only had the transfer box off but it's deffunately noiay now and wasn't before

A silly question, but is it worth checking the oil level in the t box? cannot hurt to top it up.

Cheers

neilly said:

A silly question, but is it worth checking the oil level in the t box? cannot hurt to top it up.

Cheers

Click to expand...

I will check it tommorow ,you're right ,they could have forgotten to put any oil back in transfer box ,it wouldn't surprise me !!

It might be fresh oil leaking or it might be residual from what leaked out before. My recent transfer box oil leak was mainly coming out between the brake drum and the rear prop because the nut had come loose that holds the output flange on, and the oil was getting out past the fibre washer.

Regarding the clunk on drive take-up (and overrun sometimes) my biggest improvement was in replacing the half shafts and drive flanges on the hubs. A lot of it seemed to be coming from a tiny bit of slack at the rear hubs. Additional improvements have occurred as I've replaced the rear suspension bushes and ball joint, but most of it seemed to be in the flanges!

It might seem a stupid question but how can I check the half shafts ?

What is worrying me the most is the new noise I'm now hearing since it's been in the garage ,it's a hard banging noise coming when I change down from 4th into 3rd and release clutch ,I can actually feel it through gear lever and it wasn't doing it before.

another thing someone should check is the length of the top bolt that secure t/box to g/box on rhs just under hi low selector housing on t/box a too long one will contact the intermediate gear, it has to be the shortest of the 6 that secure the t/box

When I was searching for my "clunk" , I put the whole thing up on axle stands, and then went thru each part, turning, watching and listening to each section. To try and define how one part was affected by another. Rear wheel to rear wheel, Rear wheel to rear prop, Rear prop to front prop etc.

Also, you can remove the rear half shafts easily enough to visually check them if you feel they have a bit of slop in them.

Cheers

If the tranny box oil seals were passing its possible that the output shafts are worn as well, just changing the seals if the shafts were worn as well may not stop all the leaks. Might be calling things by the wrong names there, James will know.

drive flanges and the front one is often pitted and grooved rear seldom is as its protected by the hand brake assembly

Thanks for the replys ,James,what would happen if this was the case and the long bolt had been put in by mistake as I've now found low range box seems stuck in H

noise,clunking etc,stuck in high would seem a different issue ,does hi/lo lever move or is it solid

The lever is stuck solid

was it before or had you never tried it for awhile