disco tdi series 1 transfer box diagram

Can you describe the 'clunk' in more detail.

Is it only in a certain gear or speed ?

Does it only occur when accelerating (or braking)?

Is the clunk 'felt' through the pedals as well as being heard?

Sounds like it could be in the drive train.

Get underneath and see if you can twist the front and rear drive shaft back and forth. If there is any slack you will feel it. If you find which shaft has movement you may even be able to reproduce the 'clunk' by hand.

I am sure that there will be someone else on this forum who give you more info after you report back having tried the above.

Hi Lenni.

Could well be wear in the input shaft and output gearbox shaft at transfer case end. ( landys vunerable in that area). Also wear in the drive hubs and axle splines will give a clunk. Process of elimitation Im afraid, stick with it once you get them right you will have a good run.

Cheers Axle

At the best of times, Discos have a slack drivetrain that causes the occassional knock and bang - however.

The most likely cause is a worn spline on the output shaft/input cog of the gearbox transfer case interface. Oil has difficulty getting onto the spline of the gearbox output shaft where the input cog of the transfer case slides along it. I assume you car has done somewhere around 200,000km as this is the time the problem starts to show. Post 96 models have a cross drilled input cog that allows oil into lubricate the splines.

The cog wears about 2 times faster than the output shaft of the gearbox so if this problem has just started the spline should still be OK. A new cross drilled cog costs about $400 and can be fitted without removing the gearbox or transfer case - the plate at the rear of the transfer case just needs to be removed (where the power take off used to be in older landies).

However if the splines on the geabox output shaft are badly worn then that means pulling down the gearbox.

As always though, check the easy things first - propeller shaft splines and universals, hub splines on the axles and another thing that can clunk is the ball joint on the rear suspension yoke - if your car is high milage I would definitely check this. Relatively cheap to fix.

Garry

Thanks to both of you, you have been very helpful.
We will go and investigate further and get back to you with our findings. Do you know where we can get a diagram of the transfer case from?
Talk to you soon

Lenni

I think the problem won't be in the transfer case but more likely in the diff or drive train. Good luck.

Have you looked at the rubber "donut" drive shaft connection to the rear diff. This and the ball joint on the rear axle A bracket are the two most likely offenders.
Noises from the transfer case are usually muffled by the oil circulation.
Good luck sorting it, Disco's, love em! (mines a '97 tdi)
kesh

A very common reason for a clunk in a Disco is that the ball joint which locates the rear axle to the "A" frame has become worn.

Get a big screwdriver between the A frame and axle and see if there is any movement. If yes replace.
Regards Philip A

Thanks we will look at this. You have been very very helpful we will keep in touch and let you know the outcome. Thankyou
Lenni

Lenni,
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Cheers
Mark