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Home > Puma (Tdci) > increased engine and gearbox noise after clutch/lt230 swap

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boxoftricks

Member Since: 06 Feb 2019
Location: Home Counties
Posts: 747

2011 Defender 110 Puma 2.4 USW Zermatt Silver

Is the increase in noise because the exhaust has not been correctly refitted when they have take the central part out to drop the box. Have they forced something that has misaligned the exhaust to manifold? Bit of a long shot but worth checking.

10th Aug 2019 10:21am

Mike_E

Member Since: 13 Apr 2017
Location: Aberdeenshire
Posts: 161

2015 Defender 90 Puma 2.2 HT Aintree Green

problem solved! the thing that tipped it over the edge for me is the missus was in the car when we took the trailer off to the tip and she said that it sounded a hell of a lot noisier than usual.... her words were "did they forget to put the sound deadening back in?"

so i stripped out the interior piece by piece and found three issues;

1) seal around the plastic transmission tunnel was not fitted right - the rear half of it was just hanging there which gave me a 1/2" gap all the way aroudn the back of the gear shifters... no wonder it was noisy.
2) the plastic cover over the transfer case linkage was out of place and stuck between the shifter and the transmission tunnel
3) the cover over the transfer case (under the cubby) was not sitting flush.

I sorted out 1 and 2, then for 3) I added some foam draft excluder strip on the edges of the panel and bent it back down to get to seal.

Started it up and low and behold - silence (well in defender terms) was re-instated. As the interior was so stipped down (seats out, seat box vinyl out etc) I thought as good as time as any and I used the last of the 2mm silent coat and 9mm dodomat to coat the entire seat box and foot wells. I put the dodo mat inside the seatbox where possible to let the vinyl matting sit OK and also not to foul the doors when they are shut.

I cant believe how much difference that made! I had already done the entire rear floor, hardtop sides and the entire roof with the silent coat and dodomat but did nto expect the footwells and seatbox to make so much difference.

Click image to enlarge

Click image to enlarge

spotted some wear on the nylon cage of the shifter too.... see link... everything looked OK and unworn, but might try a new cage 1st as its a cheap option.

Cheers
Mike

[/img]

11th Aug 2019 10:01pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17444

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

That is shocking workmanship by the garage and I would certainly never take any business there in the future.

12th Aug 2019 7:45am

LR90XS2011

Member Since: 05 Apr 2011
Location: bickenhill
Posts: 3644

2011 Defender 90 Puma 2.4 XS CSW Galway Green

LR90XS2011 wrote:
you state you noticed it was noisier as soon as you started it, if its noisier in neutral when stationary then its nothing to do with the transfer box or adaptor shaft as they are doing nothing and are stationary, its unlikely to be the gearbox as not much is happening in there so its probably either the clutch is noisy for some reason (unlikely) so probably a panel, floor seal or sound proofing issue, or there may be something loose underneath like the exhaust

feels good to diagnose things from the settee, glad its sorted, DEFENDER 90 TDCI XS,

I hope everyone is well and your land rovers make you happy

13th Aug 2019 5:05pm

Mike_E

Member Since: 13 Apr 2017
Location: Aberdeenshire
Posts: 161

👍 thanks for the heads up.

13th Aug 2019 6:45pm

Zed

Member Since: 07 Oct 2017
Location: In the woods
Posts: 3313

2010 Defender 110 Puma 2.4 XS CSW Santorini Black

LR90XS2011 wrote:
LR90XS2011 wrote:
you state you noticed it was noisier as soon as you started it, if its noisier in neutral when stationary then its nothing to do with the transfer box or adaptor shaft as they are doing nothing and are stationary, its unlikely to be the gearbox as not much is happening in there so its probably either the clutch is noisy for some reason (unlikely) so probably a panel, floor seal or sound proofing issue, or there may be something loose underneath like the exhaust

feels good to diagnose things from the settee, glad its sorted,

Excellent work.

I lost my knife sharpener yesterday. Do you know where it is?

13th Aug 2019 7:01pm

LR90XS2011

Member Since: 05 Apr 2011
Location: bickenhill
Posts: 3644

LOL

Not having much luck with the LOTTO DEFENDER 90 TDCI XS,

I hope everyone is well and your land rovers make you happy

13th Aug 2019 8:04pm

flyingfab

Member Since: 14 Jun 2015
Location: Brittany
Posts: 60

2015 Defender 90 Puma 2.2 XS CSW Indus Silver

Hi Mike,

I would still be very concerned about the gearbox's top up they did. Overfilling the MT-82 is not an uncommon mistake. Considering your garage's work on the covers and what they told you, I would take their incompetence for granted and assume they actually overfilled the gearbox. Adding 1,5l sounds astonishing.

If overfilled, it will eventually cause a shaft seal failure, due to overpressure when the gearbox is warm. If it was my Defender, I wouldn't hesitate : I would go for oil replacement asap and refill with the proper amount (2,2l and nothing more).

It might be for nothing... but I do believe it's worth the shot. It will definitely be much cheaper than replacing the seal when it fails

Cheers,
Fabien

14th Aug 2019 10:46pm

Mike_E

Member Since: 13 Apr 2017
Location: Aberdeenshire
Posts: 161

Agreed. I am 100% sute its overfilled.

I was waiting for the magnetic drain plug which just just avarived as did 3ltrs if the correct ford spec oil for the mt82. I'll be doing it tomorrow!

Thanks

15th Aug 2019 7:27am

Mike_E

Member Since: 13 Apr 2017
Location: Aberdeenshire
Posts: 161

Dropped the oil out of the gearbox... 3.7ltrs.

Ie 2.2 + the 1.5 they added.. will speak with garage on Monday.

A little worrying is whilst under there I thought I'd do the diffs and also change the transfer case oil. I always do this after an engine rebuild or similar after a few hundred miles to get rid of any swarf. Diffs went fine, no issues. Dropped the oil out of the transfer case and it looked filthy. Its only done 300miles!

Will email the photos to Ashcroft tomorrow to see what they think.

Mik

17th Aug 2019 7:58pm

Mike_E

Member Since: 13 Apr 2017
Location: Aberdeenshire
Posts: 161

Click image to enlarge

17th Aug 2019 8:12pm

Zed

Member Since: 07 Oct 2017
Location: In the woods
Posts: 3313

That's outrageous. I'd be livid.

17th Aug 2019 8:30pm

BenB8man

Member Since: 22 Mar 2017
Location: Norfolk
Posts: 429

2010 Defender 110 Puma 2.4 DCPU Stornoway Grey

Yup, likewise. Furious. Keep you cool but be firm. This could have seriously shortened the life of your box, seals etc.

17th Aug 2019 8:32pm

Zed

Member Since: 07 Oct 2017
Location: In the woods
Posts: 3313

Also by the sounds of it they over fill every Defender. Goodness knows how many will be affected.

17th Aug 2019 8:35pm

Mike_E

Member Since: 13 Apr 2017
Location: Aberdeenshire
Posts: 161

Those photos are the oil from the recon lt230 at 300 miles...

17th Aug 2019 10:07pm

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