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Whitewaitress

Member Since: 26 Nov 2013
Location: Liverpool
Posts: 47

Transfer Box or Clutch Failure??

2007 2.4tdci 110 Hard Top Puma on ~100k miles

Perhaps someone may have experienced a similar issue here - whilest out driving a few days ago I was changing down through the gears coming up to a set of lights when I heard a squelching noise and something clunk/knock hard from underneath.

After this I was able to limp home with a very loud whining from the gearbox/transfer box through the vehicle - closer to home when stopping at lights I would pull off gently and I could feel a slippling between the revs and the output at the wheels as if something between the clutch / gearbox / props was not engaging and here the knocking/screaching noise was coming from.

When I put the vehichle into neutral and roll the clunk/knock is still there and can be felt when it hits as if the brakes are given a sharp stab. When pulling off gently now to move it about the transmission will almost lock and I cannot push any further past this point.

Could this be a transfer box issue, or a clutch that has broken? Or even a front or rear diff?

Any guidance as always would be much appreciated.

20th Jan 2014 10:11am

geobloke

Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4410

The only way you are going to be able to tell where the clunk clack bang is coming from is by jacking up a wheel and turning it by hand, listening for scraping clunking noises. It may be neither the clutch nor the transferbox... Could be one of the differentials, or a UJ or indeed the transfer brake. Just remember to chock your wheels before jacking then release the transfer brake. Let us know how you get on.

20th Jan 2014 10:20am

Whitewaitress

Member Since: 26 Nov 2013
Location: Liverpool
Posts: 47

Thanks Guy,

I will check the movement in the wheels, the noise sounds exaclty like that in this youtube video at around 16 and 40 seconds. The clatter and screech are very similar.

Cheers,

Rob

20th Jan 2014 1:11pm

bob neville

Member Since: 30 Apr 2009
Location: Marbella
Posts: 3248

Hi Rob

Have a read, not saying it is this but there have been a few with the same problem.

http://www.defender2.net/forum/topic11955.html

Bob 2015 Jaguar XE240 R Sport - goes like ....... !!
2013 Defender 90 CSW - sold
2009 Defender 110 Double Cab - sold
2001 TD5 90 CSW - offroad project - sold to a forum member
2011 Porsche Boxster - for the sunny days !

20th Jan 2014 1:33pm

geobloke

Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4410

Whitewaitress wrote:
Thanks Guy,

I will check the movement in the wheels, the noise sounds exaclty like that in this youtube video at around 16 and 40 seconds. The clatter and screech are very similar.

Cheers,

Rob

If you cannot hear anything it would be a good idea to dump the oil from the axles first, then the transferbox and see what comes out. If something has gone then you should see chunks in the oil and the diff pan or transfer box. Open up the filler plug as well and shine a torch in there too, if the gears have eaten themsleves it will be very obvious.

I suspect it is not the front diff as having had that go on my 2002 110 you know when it does.. rear wheels almost came off the ground when that seized up.

This is what it looked like when I drained the oil and took the diff out;

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Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated

20th Jan 2014 1:55pm

Whitewaitress

Member Since: 26 Nov 2013
Location: Liverpool
Posts: 47

Cheers guys - not had chance yet to investigate any further, although one of the guys who works over the road from me seems to think its the splines on the main shaft that comes from the gearbox, and that they have worn with them not bein lubricated. He took a quick listen and came up with this diagnosis straight away.

I will keep you posted - fingers crossed the transfer box isn't another made of cheese!

21st Jan 2014 12:42pm

bob neville

Member Since: 30 Apr 2009
Location: Marbella
Posts: 3248

That was exactly the problem I had and posted in the link above. The shaft goes before the transfer box - hopefully !

Not uncommon.

Bob 2015 Jaguar XE240 R Sport - goes like ....... !!
2013 Defender 90 CSW - sold
2009 Defender 110 Double Cab - sold
2001 TD5 90 CSW - offroad project - sold to a forum member
2011 Porsche Boxster - for the sunny days !

21st Jan 2014 1:18pm

Whitewaitress

Member Since: 26 Nov 2013
Location: Liverpool
Posts: 47

Cheers Bob - I did find your thread useful reading - I'm hoping that is the extent of the problem and nothing further!!

21st Jan 2014 2:59pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17355

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

If your failure was the adaptor shaft I doubt you'd have any drive at all.

I can say this with some confidence since I am writing this while waiting for the RAC to come to take me home after suffering an adaptor shaft failure.

21st Jan 2014 5:23pm

Whitewaitress

Member Since: 26 Nov 2013
Location: Liverpool
Posts: 47

Quick update for those who have posted / read this thread:

Problem was the transfer box - the internals had shattered to bits - could have been caused by one fragment coming away from a cog or bearings failing. I'm not completely sure.

I had hoped it would be a mainshaft but sadly it wasn't!!

It's worrying that you could be plodding along anywhere in the world and something like this go 'bang' on you!!

Thanks to all of your input guys!!

16th Feb 2014 8:40pm

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