Ok this is not a normal clunk. the same problem as the other post. my question is how does atf fluid in the t-case work and why atf and not gear oil as it is a gear box? I have 01 d2 with 54k just did tranny ,diffs ,plugs engine oil did not do t-case as atf made no sence? the problem is only when driving freeway speeds and only when cruising. Any help. thnx.

 

You should never use ATF in a D2 t/case, it will kill the gears real quick.
Why do you think your t/case is clunking?
Mike

 

I dont know? like the other post on clunking it is a puzzle. She shifts smooth and firm when in town but once on the freeway and after a few miles 5-10 when trying to hold a constant (say 70mph) every time I let the gas and back on it feels like being smacked from the rear.???? the front drive shaft is new I had a LR tec tighten the rear drive shaft and check all u-joints. So t-case ?? . Does the 2001 d2 have a viscous coupling in the t-case?? If so when the rear drive shaft came loose (front bolts) could that have damaged it. HELP. thanks

 

Well, something related to the transfer case would be my guess as well. Either a low fluid level, orlash, or ?? - I wrote the other post on the "Clunking - but not like the other discos". There really is not much at all to the transfer case - no viscous coupling - just two sets of different ratio gears, a dog-type-engagement selector, and a differential. All that stuff is very robust. But, it is going to cost me nothing but a few hours of time (and a new input shaft seal) to replace my t-case. I have a better one sitting on the floor of my shop taking up room. By better I mean one with a locking differential and 1/5 the miles of my Disco. Should be able to do this in the next week or two so I'll let you know if that is the cure for our problem.

If you figure out what the issue is before then definitely let me know!!

Piotr

 

Have you greased both the drive shafts slip joints, if not pull the plugs and grease them well. Do you have a roto flex rear connection to the rear diff, is it cracked?
All Rover, Ful Time 4X4's, have a small amount of klunk, if your's has more than you may, if you have CDL want to remove one drive shaft at a time and drive on just one,see what happens.
Mike

 

I forgot to mention that when I put the truck into gear and press the brakes it seems to muffle the noise.

 

Huh? This post is 9 years old...