DEFENDER2.NET - View topic - Gearbox Rattling Noise... Clutch replaced with HD! :(

↓ Advertise on Defender2 ↓

Home · FAQ · New Posts · My Posts · PMs · Search · Members · Map · Calendar · Profile · Donate · Register · Log In

Home > Puma (Tdci) > Gearbox Rattling Noise... Clutch replaced with HD! :(

Page 1 of 2

Print this entire topic ·

PCA42

Member Since: 15 Jun 2014
Location: Church Stretton
Posts: 468

2008 Defender 110 Puma 2.4 DCPU Tonga Green

Gearbox Rattling Noise... Clutch replaced with HD! :(

Hi all,

I've just collected my 2.4 110 from the garage after they put a new Truckfix ceramic clutch kit in and an Ashcroft upgraded adapter shaft kit.

Driving it home, clutch wise it feels excellent even though it's still got 500 miles to bed in yet.

Backlash wise, it's disappeared... no nasty clonk taking up drive!

However, the rattling noise in neutral is still there (disappears when clutch depressed) and is even worse (louder), and in gear it's a little rattly too... 6th gear is completely unusable though, makes an awful racket that almost sounds similar to something hitting the exhaust pipe, if that makes sense!

Too late in the day to take it back to the garage, but will be first thing tomorrow. They did say there was fine swarf in the gear oil. Any ideas what this could be? Sounds like my gearbox is f**ked to me!

Looking at the old clutch, it was like a tamborine... So you'd imagine that to have been a cause of the noise... which it may have been originally.

Looking at the old adapter shaft, it doesn't seem to bad to be honest (vehicle on 66k miles). Can't detect any lateral play in the splines, but if you try and move it up and down in the coupling, there is some minor play. Could that have caused the input shaft of the gearbox to move, causing excessive gear wear hence the swarf?

Think this may be an even bigger bill to come

Pete

2010 Discovery 4 GS TDV6
1972 Series III 88" 2.25P

Last edited by PCA42 on 19th Sep 2016 8:49pm. Edited 1 time in total

19th Sep 2016 4:38pm

Mjibex

Member Since: 21 Mar 2013
Location: Reading
Posts: 283

2013 Defender 110 Puma 2.2 XS CSW Loire Blue

I have the Truckfix ceramic clutch kit too from Ian at IRB - he advised that there would be more noise at idle and this will be worse than a standard new clutch; I guess this is due to the springs being stronger and don't damp the oscillations as well.
As opposed to the worn clutch which gives a similar noise due to the springs leaping around.

With regards to your other comment - I have the exact same issue. Under 2000RPM, under any throttle, 4th, 5th & 6th gear give the noise you describe; I would guess this is for the same reason as above. 3rd is a little rougher under 2000RPM but no real concern. 6th will be fine over 55/60ish.

However as a plus note things are settling down a bit now a few miles have been added.

I would say if you are a low speed / low rev changer this would not be the clutch for you.

Regards

Mark.

19th Sep 2016 5:01pm

PCA42

Member Since: 15 Jun 2014
Location: Church Stretton
Posts: 468

Hi Mark,

Thanks for your reply. It does sound extremely harsh however especially in 6th, sounds like something broken to me. Is yours that harsh or just a little bit?

Is it just a case of putting up with it until it's bedded in; as Truckfix say you shouldn't really run over 2000rpm for the first 500 miles or so? Pete

2010 Discovery 4 GS TDV6
1972 Series III 88" 2.25P

19th Sep 2016 5:31pm

Roy5695

Member Since: 15 Feb 2014
Location: Cornwall
Posts: 1123

2011 Defender 110 Puma 2.2 XS DCPU Indus Silver

It's not just the weights on your gearstick is it? Whilst driving try and squeeze the bottom of the stick and see if it gets better.

19th Sep 2016 5:38pm

PCA42

Member Since: 15 Jun 2014
Location: Church Stretton
Posts: 468

Nah it's louder than that Roy haha.

Just given it another test drive, and as you said Mark, it quietens off above 55-60 back to usual. But trying to drive under 2000rpm for the bed in period means it makes a lot of noise until you reach that speed in 6th. I tend to be a bit of a revver before changing up a gear as I found it makes things smoother, but trying to be sensible and stick to Truckfix's recommendations. Pete

2010 Discovery 4 GS TDV6
1972 Series III 88" 2.25P

19th Sep 2016 6:07pm

Mother superior

Member Since: 05 Aug 2013
Location: Surrey
Posts: 504

Mate
I feel your pain, my 110 has just clocked 60K and believe it or not has also just had a new clutch and now sounds like nuts being dropped in a food mixer, just like you described, my local man ( challenger 4X4 ) thinks could be main shaft bearings..... But won't know till he's been in.
It's only money, what else would you do with it?
Wes Oh woe, oh woe
My crusty old landrover,
It will not go.

19th Sep 2016 6:50pm

PCA42

Member Since: 15 Jun 2014
Location: Church Stretton
Posts: 468

Oh dear, that aint good. Let us know how you get on with that. Pete

2010 Discovery 4 GS TDV6
1972 Series III 88" 2.25P

19th Sep 2016 7:19pm

Mother superior

Member Since: 05 Aug 2013
Location: Surrey
Posts: 504

Maybe we should start a support group

Oh woe, oh woe
My crusty old landrover,
It will not go.

19th Sep 2016 7:48pm

Mjibex

Member Since: 21 Mar 2013
Location: Reading
Posts: 283

PCA42 wrote:
Hi Mark,

Thanks for your reply. It does sound extremely harsh however especially in 6th, sounds like something broken to me. Is yours that harsh or just a little bit?

Is it just a case of putting up with it until it's bedded in; as Truckfix say you shouldn't really run over 2000rpm for the first 500 miles or so?

Yes very harsh - I would not drive under 2000 RPM as it does not feel mechanically sympathetic enough to me. Plus I didn't have that info at the time (I just wouldn't beast the clutch).

My original clutch was fine (completely silent - no issues), gearbox was out for leaking rear main at 27,500/28,000 miles. So I think it is definitely clutch characteristic.

I also think that it shows/highlights the stress a normal clutch is under when under load under 2000rpm in higher gears and this maybe a contributory factor for early failure.

Regards Mark.

19th Sep 2016 7:56pm

jwb

Member Since: 30 Oct 2012
Location: Los Angeles
Posts: 27

Gents, you are making me a bit nervous about my recent Truckfix clutch order. I bought their HD1 lined kit which is the most "HD" liner described on their website; it may be ceramic based but doesn't state that. Direct link below to a picture on their facebook site which shows the instructions of 300 mile bed-in under 2000rpm (with lots of shifts being the key).

Is this the same clutch you have installed or do you have a ceramic paddle style?

https://scontent-iad3-1.xx.fbcdn.net/v/t1....e=5868FAB3

20th Sep 2016 11:44am

Mjibex

Member Since: 21 Mar 2013
Location: Reading
Posts: 283

Mine is ceramic paddle.

Regards

Mark.

20th Sep 2016 2:49pm

jwb

Member Since: 30 Oct 2012
Location: Los Angeles
Posts: 27

Thank Mark, I didn't realize the puma ceramic paddles were Truckfix, good to know. I wonder how their HD1 style will compare. Unfortunately, it will be a while before I install mine.

21st Sep 2016 12:01pm

PCA42

Member Since: 15 Jun 2014
Location: Church Stretton
Posts: 468

One for you this Mark:

How much does your clutch/gearbox rattle at idle?

Mine isn't really audible when the vehicle is cold, but once warmed up the chatter is really loud (goes away when clutch dipped, or the engine speed raised). Bit embarrassing sitting alongside people in traffic, sounds like a knackered tractor haha!

Seems to be getting a bit better now there's over 200 miles on it; still a bit noisy in high gears when the engine is on load undera about 1750rpm, but again I think that must be just clutch/box chatter? Pete

2010 Discovery 4 GS TDV6
1972 Series III 88" 2.25P

24th Sep 2016 10:12pm

Mjibex

Member Since: 21 Mar 2013
Location: Reading
Posts: 283

Silent when cold - loud when warm also.

25th Sep 2016 7:35am

PCA42

Member Since: 15 Jun 2014
Location: Church Stretton
Posts: 468

Thanks Mark.

Doesn't sound healthy but there we go, time will tell how it goes! I'll have to grin and bear the noise

Pete

2010 Discovery 4 GS TDV6
1972 Series III 88" 2.25P

25th Sep 2016 9:05pm

Page 1 of 2

All times are GMT

Jump to

< Previous Topic | Next Topic >

Posting Rules

You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum