By Bill Lux on Tuesday, November 06, 2001 - 11:00 pm: Edit

Hi folks - I am a new Discovery owner of a used 1994 with the 5 speed manual. I thought the u joints were worn because it clunks when shifting, unless I am very (very!) easy with the clutch. Checking the joints, they seem tight, and the splined shaft seems tight. The rubber joint at the rear drive shaft needs replacing, but there seemd to be huge amounts of play where the front prop shaft enters the transfer case. Any suggestions? Thanks for your advice.

By jp on Wednesday, November 07, 2001 - 12:35 am: Edit

If you mean rotational play, not radial, that sounds like the mainshaft to transfer gear splines are worn. Find the suffix letter of your transfer box, then look up the TSB on the modified transfer gear, and see if you are in/out of luck. The gear was modded to have longer splines inside, and cross drilled to allow oil in, to reduce this wear. Usually it means a main box rebuild for a new mainshaft, and a new transfer gear - about GBP100 each part, but rebuild is a few more $$$$$. You can replace the gear by itself without much dismantling, but I found it didnt help much if the mainshaft is worn. Check the A frame ball joint first though- this can make similar noises.

By Dan Rork on Wednesday, November 07, 2001 - 11:51 am: Edit

Make shure you have the diff lock on when checking the play in the transfer case. When you don't have it on the shafts are free to spin independantly limited by the front or rear diff. I did the same thing before I realized that it was just running free with the center diff unlocked. Just my 2 cents.

By Neil Cawley on Thursday, November 08, 2001 - 08:03 am: Edit

I too have a 5 speed 94. I have had manual transmission cars/trucks for 30 years and I find the Discovery a difficult vehicle to drive smoothly. Perhaps it is the 4 wheel drive but mine has always felt clunky to me. I think it is the nature of the beast. One thing I did was to replace both the transmission fluid and the transfer case fluid with Redline MTL. Really reduced the noise from these units. Still drives clunky.
neil

By johnvigg on Thursday, November 08, 2001 - 09:48 am: Edit

My 95 is the same way, and another person on a yahoo disco group was complaining about the clunking too. I just atribute it to being a Rover
I'd hope with only 34k on it that theres no problems
john