You can drive it with front shaft removed IF you engage the CDL (lock) on the transfer case, but I don't know if matters for how long.

That's actually a good test. Remove the front shaft, lock the CDL and drive it. See if the noise is gone.

 

I checked the prop shaft – appears to be OEM, no zerks – and there doesn't seem to be any play in it (yanked on it heartily). I jacked up one side of the front, put it in neutral, and spun the wheel: Nothing unusual, no clacking, and just the little bit of diff slop when rotating the tire forward and reverse.

Tomorrow I'm going to get both front wheels off the ground and (carefully) see if I can recreate the sound by putting it in drive (should be fine with the CDL unlocked, right?). Then I guess I'll drop the front driveshaft, lock the CDL and see if it's still there.

I need a third car! We had to rent a car because both of ours are out of commission until Monday – hopefully my E30 (w/ an S52 drivetrain swap) will have its vibration problems resolved by the rebuilt driveshaft I picked up today…

 

If there's no grease fittings on the shaft, it's prob the original.

I'd be really cautious about having it off the ground and putting in gear. All four is ideal and can still be dangerous. In any case don't get under it or be in front of it while you're doing it.

If you can, just take front shaft off, lock the dif and drive it. Having the shaft off is a better way to inspect it anyway. If it's the original, you could very well be approaching the end of it's life. If you're not familiar with this issue....if it breaks while driving, it will very likely destroy your tranny when it breaks. That's why everyone jumps to addressing that issue 1st.

Two other things you can try (even thought they prob won't work) to locate the noise are: 1) before you remove the front shaft, gently drive it in 4low and see if make the noise still. If it doesn't it could be from the transfer case. 2) get the front tires off the the ground, parking brake on, put the transfer case in neutral, and spin each of the front tires by hand and see if you're hearing/feeling anything. Not sure you'll be able spin it fast enough though, but won't have engine noise and you'll be right there.

 

I got both front wheels up and the noise is loudest at about 13mph. Here's a video that contains the sound. I'm going to pull off the driveshaft later today. I'm assuming that it won't make the sound anymore once I do that, but how do I figure out if it's the driveshaft that's the problem (and not the diff or beyond)?

https://www.youtube.com/watch?v=hVVH...ature=youtu.be

 

pull the shaft check it closely on the transfer case side

 

These rovers take a lot of maintenance. You are going to have to become very intimate with this vehicle. Its a good solid car as long as you give it much attention. I lube my drive shafts every oil change. The front shaft is due for 3rd rebuild in the 10 years I've own her. I have play in the universal joints even with the constant lubbing. Its the trade off I guess. Oh well. Rover fan for life!!

 

Your kidding right?

 

Can't tell if you're telling him not to or that it's okay...?

 

Out with the old and in with the new! New driveshaft from British Parts of Utah solved the clacking. (Now I just hope that my torquing was enough because I could not for the life of me get a torque wrench on those bolts…)

Interestingly, it looks like the old driveshaft might not've been the original as it had a zerk on the front u-joint, but none on the rear double. I somehow managed to miss it when I was looking for it. No idea if greasing it (instead of buying a new one) would've helped. What do I do with the old one?

So, at every oil change, grease the four zerks? Green Grease? Synthetic?

 

Im also wondering what to do with the old one. I'm guessing keep in in the garage until it's never needed, then throw it away when I come to move house. But that's just a guess.