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eutek



Member Since: 03 Mar 2009
Location: High Wycombe
Posts: 586

United Kingdom 2009 Defender 110 Puma 2.4 XS CSW Stornoway Grey
Clunk partially sorted... but one noise remains!
About a week and a half ago my 110 was brought in to a main LR dealer, and they managed to resolve the main clunking problem I was having with my gearbox. They said that there were two issues, something to do with excessive flange as well as pinion clearance. I'm not a mechanic myself - as you can probably tell by my less-than-technical descriptions.

The 110 is much easier to drive, gear changes are much smoother... However I still have a secondary clunk that persists. I did point this out to them, and the mechanic heard it as well. This secondary sound came about after the truck's 12K service. I was told that there was a rear diff oil leak, and that they'd sorted this. Ever since I got the truck back from this particular garage I've had this sound.

I can re-create it if I move along in 1st and blip the accelerator. As the bulk of the truck moves forward, there is a "clunk/pop" - and a similar sound as the momentum changes when it slows down.

It isn't the same as the original gearbox clunk, it is a higher-pitched sound, almost like a "pop POP". If I downshift it doesn't really appear until I get from 5th to 4th, however it isn't that apparent. It is much louder in the lower gears.

If I just stop the truck with brakes - it doesn't appear at all. I thought it might be something loose underneath banging around, but I can't find anything. It only seems to occur when momentum changes. When I move off, it does it and as long as I'm moving forward it doesn't reoccur. As soon as I slow down it appears - just once, until I re-apply power and move forward again.

Does this description make any sense to anyone? I'm a bit nervous as I've got a huge cross continent trip coming up on Saturday - I don't want to suddenly run into a critical gearbox issue in the middle of Eastern Europe!
Post #35290 29th Jun 2010 7:18am
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dgardel



Member Since: 30 Nov 2008
Location: Veneto (Heart & Head)
Posts: 3586

Italy 
Re: Clunk partially sorted... but one noise remains!
eutek wrote:
................

I can re-create it if I move along in 1st and blip the accelerator. .............


I think is quite normal in this case, I tried with a Toyota 95 and it make the same "effect".....

due to the "natural" transmission (all transmission) gears play.....

you have
1. a gearbox
2. a transfer
3. 2 diffs (gear and pinion)

do not compare to a "normal car" Discovery 5 td6 HSE Stornoway Gray Outback Engineering Limited Edition

IID Pro MV License
Post #35293 29th Jun 2010 8:17am
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Cannonball



Member Since: 19 Jun 2009
Location: Co Laois
Posts: 150

Ireland 2008 Defender 110 Puma 2.4 XS CSW Stornoway Grey
Almost exactly the same symptoms on my 2008MY 110 from new. Some dealers maintain that you will always get some clunking, but I have driven quite a few TD5 models over the last ten years and two 2009MY TDCi vehicles last year that don't have this problem. Everyone who is travelling in it comments on it and I feel that should I trade it in/sell it next year a prospective dealer/buyer would not be happy with the clunking. Incidentally, I also have some backlash emanating from the rear differential. My dealer is currently awaiting approval from LRUK to replace it under warranty and I hope this finally resolves the issue. Good luck with yours.
Post #35294 29th Jun 2010 8:42am
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eutek



Member Since: 03 Mar 2009
Location: High Wycombe
Posts: 586

United Kingdom 2009 Defender 110 Puma 2.4 XS CSW Stornoway Grey
Grazie mille per la risposta... Volevo essere sicuro che non e' un problema con il cambio! Very Happy

Non vorrei rimanere "bloccato" senza macchina in Ungheria o Romania!
Post #35295 29th Jun 2010 8:44am
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eutek



Member Since: 03 Mar 2009
Location: High Wycombe
Posts: 586

United Kingdom 2009 Defender 110 Puma 2.4 XS CSW Stornoway Grey
Thanks guys. Just a bit nervous before a big trip East.

I took it on a 1500 mile "shakedown" run to France recently, before the major clunking was fixed, and it ran fine - just popped/clunked along.

About two years ago I returned to the UK from Eastern Europe with the missus' Mercedes loaded with part of our belongings (long story), however the auto gearbox started to fail and we ran into blizzards, torrential rain, mud etc. I was concerned that we would break down along the way.

We barely made it back to the UK, but ever since then I've been really paranoid about long trips!
Post #35296 29th Jun 2010 8:49am
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eutek



Member Since: 03 Mar 2009
Location: High Wycombe
Posts: 586

United Kingdom 2009 Defender 110 Puma 2.4 XS CSW Stornoway Grey
As the noise started to become noticeable, I popped in to the local LR garage. They agreed to look at the truck w/ short notice, and after a few hours of poking around ascertained that it is the drive shaft making the noise.

They're going to swap it out tomorrow. Hopefully this sorts it and doesn't introduce a whole new raft of issues.
Post #35416 1st Jul 2010 9:17am
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eutek



Member Since: 03 Mar 2009
Location: High Wycombe
Posts: 586

United Kingdom 2009 Defender 110 Puma 2.4 XS CSW Stornoway Grey
A wee update...
A wee update...

They gave me back the truck last night, as the part was ordered to be fitted today. However somehow the new drive shaft was sent to another location, so no/go.

The good news is that they managed to take a lot of the backlash out. When I picked it up last night, it was like driving a different Defender. The mechanic said that he adjusted the flange clearance in the rear diff, and this took out the major "pop" sound that I'd been hearing.

The drive shaft still needs to be replaced, however they reckon it is still usable, however better to be replaced in the near future.

I don't know why it took me 3 different visits to three different dealers for someone to finally hear that popping sound and correctly (or partially) diagnose the issue. The first lot tried to tell me all the noise was characteristic of the marque, the second lot almost got it right. I hope that third time is the charm (fingers crossed to avoid jinxing).
Post #35479 2nd Jul 2010 12:07pm
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alwoodley72



Member Since: 14 Mar 2010
Location: salisbury, wilts
Posts: 724

England 2008 Defender 130 Puma 2.4 HCPU Alaska White
hi, i moaned and moaned to my dealer about a shunt when in town driving, technical guy came down and the usual they all do that sir ensued... came back from hols, jumped in landy after 2 weeks in the 8 tear old subaru and thought hmmmm... back to dealer for extended booked in test drive and it turns out i neede 2 new rear driveshafts, splines absolutely shagged and the short one about to shear.... a different vehicle now, just got to convince them on the throttle hesitation after the remap/2 new egr valves and the new clutch rattle.... happy days!
Post #35520 3rd Jul 2010 8:23am
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Gav110



Member Since: 14 Feb 2010
Location: Sydney
Posts: 16

Australia 
alwoodley72 wrote:
hi, i moaned and moaned to my dealer about a shunt when in town driving, technical guy came down and the usual they all do that sir ensued... came back from hols, jumped in landy after 2 weeks in the 8 tear old subaru and thought hmmmm... back to dealer for extended booked in test drive and it turns out i neede 2 new rear driveshafts, splines absolutely shagged and the short one about to shear.... a different vehicle now, just got to convince them on the throttle hesitation after the remap/2 new egr valves and the new clutch rattle.... happy days!


Good going mate - mine's going in tomorrow to address the rattle, gearbox crunch on 2nd-3rd, and the hesitation. Over the phone the service tech said that the hesitation sounded like EGR (positive start), and the rattle sounded like TC freeplay - we shall see. I have asked them to check clutch, diffs and handbrakes too - hopefully will be action Wink but have put it all in writing and documented all calls....

Let us all know how you go - I'll do same. Gav Gavster
2010 Puma 110
Post #35568 4th Jul 2010 1:41pm
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eutek



Member Since: 03 Mar 2009
Location: High Wycombe
Posts: 586

United Kingdom 2009 Defender 110 Puma 2.4 XS CSW Stornoway Grey
So... brought the 110 to the dealer in order for them to replace the rear propshaft. I also pointed out to them that several other issues appeared during our trip to Eastern Europe, namely a small leak appeared at the bottom of the gearbox (transfer gears) and the left side rear passenger door wouldn't open.

They sorted the above out. They replaced the propshaft, , plus replaced the splines (?) in the rear diff as they said the original ones were worn, sorted the gearbox leak, stuck door and applied a software update.

Result? A much quieter 110. Not only does it hardly clunk (only audible clunk is when I don't time my shifts right and let up too quickly on the clutch which happens to me on a smaller car as well), but the air intake no longer roars after long runs down the motorway.

After several hours on the autobahn, it would roar like a MiG 21 as we pulled into the rest stops, even going 5mph. It no longer does this.

The clutch pedal still squeaks and pops, but the clutch itself is sound.

Fair play to the dealer, their service was excellent. The car was washed (and waxed!?!?!) both times I picked it up.
Post #36411 16th Jul 2010 7:48am
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