I have a 2001 Disco 2. I converted the rear axle to a u joint axle that I got from a 1998 discovery. I used the flange off the 98 as well. I put in the spacer recommended by atlantic british as well as a new oil seal. It drives much better, but I get a light grinding over about 30 mph from the rear or middle. At first I thought it might be the dust cover on the flange because it was loose. I put the dust cover from my 3 bolt flange on and it was tight. The sound still occurs. It goes away when I pull my ebrake even just a little or when I'm accelerating. It only occurs when I'm coasting. My suspicion is a bear (but why would it coincide with this modification) or my parking brake. Any ideas to diagnose or tips as to what it might be? The dust shield appears to be tight now but I could take it off and run it without that to see if it changes anything.

 

did you replace the u-joints with new ones ? and is the vehicle lifted over stock ?

 

i have about 2 inches of lift might even be a little less. I did not replace the ujoints but did grease them well and they seemed to move freely.

 

Possibly the dust shield is on the wrong way and is rubbing on the pinion housing .