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rallysteve

Member Since: 10 Feb 2014
Location: Cumbria
Posts: 2237

2002 Defender 110 Td5 DCPU Keswick Green

Grinding noise when clutch released

My Td5 has started making a terrible noise over the weekend when the clutch is released when stationary (not sure if it is doing it when moving but not audible above the sound of the engine). It is most noticable from outside and although I havent investigated closely, sounds like it is coming from inside the bellhousing.

It is fitted with a LOF Single Mass Flywheel conversion which has been fine for 12months so doubtful this is the issue. Does anyone have any other ideas please?

Other than the noise, there is nothing else wrong drivability related, gearchanges are fine, not abnormal vibrations etc. Starts up fine (i.e. no bad noises from the starter which would imply it is dragging). Gearbox was fully rebuilt about 6k miles ago.

The sound almost sounds like the teeth on the flywheel ring-gear catching on something but as soon as the clutch is pressed (even 1/4 travel) the noise goes away totally!

Will try to have a closer look tonight when it is back from MOT.

Cheers,
Steve 02' 110 TD5 Double Cab Rebuild Thread

16th Sep 2024 1:55pm

rallysteve

Member Since: 10 Feb 2014
Location: Cumbria
Posts: 2237

Turns out the noise is internal to the gearbox and draining the oil has revealed a large amount of glitter and debris

02' 110 TD5 Double Cab Rebuild Thread

17th Sep 2024 8:11am

excossack

Member Since: 22 Feb 2012
Location: North West
Posts: 5855

1999 Defender 110 Td5 SW Caledonian Blue

1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock

17th Sep 2024 8:41am

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17458

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

My Disco 2 did something similar, the transmission started to make a noise very reminiscent of a coffee grinder. I don't think it was the transfer box (which I have subsequently stripped and rebuilt) and stripping the R380 is still on the "things to do when time permits" list. I bought a complete transmission from a breaker, which had far fewer miles on it than my original (which had well over 200k), and fitted that after reinstating the CDL.

I will one day get round to stripping the original box since I am intrigued what would cause it to go from "no noise" to "catastrophic noise" in a very short distance (around 30 miles). It sounded really, really bad! I was fully expecting a complete disintegration it was so bad.

I was also surprised that the s/h ex-breaker box was far nicer to drive than the original ever had been, even when the vehicle was new (I bought the vehicle new). I had always assumed that all R380s were horrible, I now realise that mine may have been unusually horrible!

17th Sep 2024 12:06pm

Will@LRW

Member Since: 04 May 2019
Location: UK
Posts: 184

1997 Defender 110 300 Tdi CSW Alpine White

Re: Grinding noise when clutch released

Not a great find Steve 🫤

I remember on mine the feeling when a bit of the syncro hub came out on the magnet...

rallysteve wrote:

It is fitted with a LOF Single Mass Flywheel conversion which has been fine for 12months so doubtful this is the issue.

I will play devil's advocate and say your statement may be confirmation bias. Ashcroft website states that a SMF on an R380 causes the symptoms you describe

https://ashcroft-transmissions.co.uk/product/r380/

Quoting:
"We have many noise issues reported on R380’s when fitted to the TD5 engines when a single mass flywheel is used instead of the stock duel mass type, the single mass flywheels make the gearboxes ‘chatter’ badly on idle and when not under load, this does not appear to be detrimental to the gearbox but does not sound good at all, we do not treat this as a gearbox fault, its caused by the single mass flywheel transferring the knock of the diesel engine to the gearbox and making the gearbox rattle." LR Workshop
Find a Defender's history and spec: https://defender.lrworkshop.com

17th Sep 2024 8:21pm

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