Hey guys. This is my first post to the forum. Love it, pull most all of my repair tips and answers from here. Trust this place. Need some help. I bought my 2004 Disco in March from a place in Atlanta, GA that I deeply question now, because of my now intensely deepening knowledge of the interworkings of this vehicle in the 5k miles I've put on it. Today, I felt:
1) A vibration increasing over 72mph, faster = more aggressive. disappears under 72mph
2) Front Drive shaft dust boot is gone. Why?
3) Incredibly violent clunk from Tranfer case from a decel to accel, more than a little clunk.
4) Front Drive shaft, solid no slop or play.
5) Rear Drive shaft, lost of play and can make it move up and down. But, the shaft and u-joints don't move. It's the pinion and past the drum that move.
6) Brake drum moves with the rear Drive shaft in rotation and up and down slop.
7) The shafts look fairly new.
8) Is now leaking from the transfer case plate just above frame connector.
9) 115k miles on it. Would not count on a straight answer from any history or service from the place I bought it.
I haven't taken anything apart yet. Or inspected any further.

Thank you all.

 

I would replace the rear output bearing first. This may fix the vibes and the clunk, but if not, it needs to be done anyhow and then you can start looking at other items in the drive train. You can do this without pulling the whole case. Very good walk through here...

https://forums.lr4x4.com/topic/6917-...l-replacement/

While the case is drained, you can pull the bottom plate and seal the lower plate if that is the source of your leak.

Most aftermarket shafts do not have the dust boot. Mine looks like this one..

 

Pull Rear Drive Shaft ASAP, remove the brake drum, and inspect the 4 mounting bolts that secure it to the transfer case. Also check the nut that secures the yoke to the transfer case.

Also since for peace of mine I'd buy a new 200.00 front drive shaft. I just pulled one from a friends D2 that "seemed" fine as he put it, but upon removal it was about to grenade his transmission & exhaust thing was completely trashed.