Clunking from gearbox when accelerating...

justincase41 · Post by **justincase41** » Sat Apr 18, 2009 11:48 pm

Howdy,
My new Brumby came with a rebuilt gearbox (Receipts and all). But when you accelerate, there is heavy clunking coming from the left hand side of the gearbox. When you are coasting along,the clunking goes away. If you hit a hill, clunking appears again. The clunking is very loud. Seems to appear whenever you loading up the motor/gearbox. My first thoughts are a stuffed inner CV race, the inner cv boot is split as well. My other thoughs are stuffed diff. Will investigate further in the morning. What does everyone else thing??

Gannon · Post by **Gannon** » Sun Apr 19, 2009 8:00 am

Yep its the inner DOJ (double offset joint) that is clunking.

When you accelerate, the front of the car lifts slightly and increases the angle of the shaft and this makes a worn DOJ clonk

AndrewT · Post by **AndrewT** » Sun Apr 19, 2009 1:10 pm

Yep, I'll second CV joint. Definitely the thing to check before you start thinking along the lines of more major problems like gearbox. Inner more likely as it doesn't seem to be affected by if you are turning a corner or not like it would with an outer.

justincase41 · Post by **justincase41** » Sun Apr 19, 2009 2:47 pm

Well, Drained the gearbox oil into a pan, came out nice and clean. No metal particles on the magnetic sump plug. Grabbed a torch and inspected the diff through the sump plug hole as best as I could. Everything seemed good.
Searched through oil pan, no metal to be found.
Then removed CV joint, stripped the inner DOJ and gave it a clean. There appears to be reasonable wear, hopefully the cause of the horrible clunking.

AlpineRaven · Post by **AlpineRaven** » Sun Apr 19, 2009 7:39 pm

Was there any clunking when you steer point to point while doing a circle? and another thing was there any vibrations in specific speed?
Is your Subaru lifted?
Cheers
AP

justincase41 · Post by **justincase41** » Sun Apr 19, 2009 7:57 pm

The Brumby is stock standard, the clunking occurs when driving in a straight line and turning. Occurs when your accelerating moderately, and going up a hill where you have to work the motor. No vibrations, just noisy clunking.

justincase41 · Post by **justincase41** » Mon Apr 20, 2009 3:31 pm

Well, the plot thickens...

Spoke with previous owner who advised that when the noise started, he had the gearbox fully rebuilt. Whilst this was being done, he installed a secondhand unit but the noise still remained. He then installed new engine and gearbox mounts, new ball joints, reco's steering rack, new clutch kit, new drivers side CV, reco tail shaft, but noise was still there after all this..... He then re-installed the reco gearbox and noise was still there.... He had enough....and thats where I came along.

Now im starting to think if its a loose or warped fly wheel. He didnt get the fly wheel machined. He laso advised that the old clutch plate was very worn, rivets pretty much exposed.

Anyone can any other suggestions.....???:(

Have ordered all new suspension bushes, front rotors and pads then of to the mechanic for a pink slip(after thumping/clinking sorted).....

justincase41 · Post by **justincase41** » Fri Apr 24, 2009 6:44 pm

Well pulled the box out today to inspect flywheel for warping and also the spiget bearing..... Just incase it is the cause of the problem. I replaced both cv's with brand new units, new rotors, pads, all front end bushes and ran the car on axle stands. I could still hear the noise when accelerating. Again the noise is a vibrating/thumping sound.
When I move the drive shaft splines, the drivers side appears to have some play.......

Fingers crossed warped flywheel or shagged spiget bearing

AlpineRaven · Post by **AlpineRaven** » Fri Apr 24, 2009 8:00 pm

justincase41 wrote:Well pulled the box out today to inspect flywheel for warping and also the spiget bearing..... Just incase it is the cause of the problem. I replaced both cv's with brand new units, new rotors, pads, all front end bushes and ran the car on axle stands. I could still hear the noise when accelerating. Again the noise is a vibrating/thumping sound.
When I move the drive shaft splines, the drivers side appears to have some play.......

Fingers crossed warped flywheel or shagged spiget bearing

I know its gonna be a pain in the arse, have you thought about swapping over the drive shafts?

Worst thing is - something might be wrong inside the gearbox?
Cheers
AP

justincase41 · Post by **justincase41** » Fri Apr 24, 2009 8:20 pm

If the flywheel and spigot bearing are all good, the gearbox has to come apart....
It's got me stumped, previous owner told me that the noise started and he removed the box, had it pro-reconditioned with all the receipts. The box took a little longer than expected so he picked up a another gearbox to use until the reco one was ready. When he installed it, it continued to make the sound.
When the reco box was re-installed, the noise was still there.

Is it something that was missed..... I know he didnt have the flywheel machined when he installed the new clutch kit and when I mentioned spigot bearing.. His reply, "Whats that?"

Stay tuned for more.........

Does anyone know where I can get a good pair of drive shafts?

DRUM ROLL .............................................

Spigot Bearing is brand new!!!! DOH.......

AlpineRaven · Post by **AlpineRaven** » Sat Apr 25, 2009 4:00 pm

Notice the circlips at the end of stub axles inside the front diff... you'll have to open up the gearbox to access, I don't believe the stub axles would be that worn out unless you have twin turbo to blow it up!!

I was thinking, I think it might be collapsed bearing inside the box somewhere. Maybe, I know it sounds risky but get a screw driver, place it on the gearbox & put it in your ear on other end in different areas and have a good listen while turning, from there go different areas to see if there is noise differences.. That would be next step before taking the box off again.
Cheers
AP

justincase41 · Post by **justincase41** » Sat Apr 25, 2009 6:41 pm

Well well well, rule number one: Dont inspect your spigon bearing at 10pm in the dark and after consuming copious amounts of alcoholic beverages.
Got home from work, removed clutch and fly wheel and discovered that the spigot bearing is stuffed. Its a sealed beaing but appears to be very dry. Give it a spin and all you get it rumbling and heaps of movement.
I think I may have discovered the problem.

Thats why when the gearbox was reco'd, problem wasn't fixed. Old owner put new clutch in but didn't replace the spigot bearing or machine flywheel. Flywheel looks good but will take in to shop to get them to check it for warpage and runout just to be safe.

Spigot bearing shopping monday morning.......

AlpineRaven · Post by **AlpineRaven** » Sat Apr 25, 2009 9:53 pm

justincase41 wrote:Well well well, rule number one: Dont inspect your spigon bearing at 10pm in the dark and after consuming copious amounts of alcoholic beverages.
Got home from work, removed clutch and fly wheel and discovered that the spigot bearing is stuffed. Its a sealed beaing but appears to be very dry. Give it a spin and all you get it rumbling and heaps of movement.
I think I may have discovered the problem.

Thats why when the gearbox was reco'd, problem wasn't fixed. Old owner put new clutch in but didn't replace the spigot bearing or machine flywheel. Flywheel looks good but will take in to shop to get them to check it for warpage and runout just to be safe.

Spigot bearing shopping monday morning.......

I don't think the spigot bearing will help with this - I might be wrong!! Because in my Liberty when I removed the gearbox about 3 weeks ago, the bearing only had 5 remaining bearings left and the cover was screwed... I knew the bearing was gone but it didn't make any clunking noises before i removed the box.

(in my opinion, the bearing will not make any noises when the clutch is not being pressed, It will make noises when you press the clutch)

I think the bearing part number is 6201 and you can get them from CBC. (I dunno what EA81 has?)

I just cannot understand why the clutch kit people do not supply spigot bearing!, but they give you throw out bearing as well the kit but missing a spigot bearing! huh... and for a bearing that small should be replaced every time when replace the clutch..

It would be worth get the flywheel machined like what I did with mine, I've noticed difference between non machined flywheel & machined..
Cheers
AP