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Rattling Sound in all gears but 4th

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Rattling Sound in all gears but 4th

Postby damo667 » Fri Oct 09, 2015 3:00 pm

Hey Guys why does your truck always break when your the furthest away from home?

I was driving up the west coast and about 50K before Greymouth started to hear a clicking sound coming from the engine or gear box,

Checked Oil in Gearbox and Transfer case.. seemed fine.. Then started to think it might be a ticking from the exhaust.

I carried on and it got louder as I thought it would if it was a hole in exhaust..

When I got to Grey and slowed down I noticed the ticking/clicking was quite loud at low revs so that made me question the exhaust theory..

I then noticed that it makes sound in ever gear but 4th.. its dead silent...



Does anyone have any ideas? What are my chances of getting back to QT in 4th :)

Cheers in advance..
vroom..._____________...........
vroom./---------|--------\.......
..&.....||______|_____O-\______....
....&...|--____---------------____--\..
........=\/-----\__________/-----\_|...
............\___/..................\___/...
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damo667
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Adjusted boost,
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"the little rihno"

Re: Rattling Sound in all gears but 4th

Postby geeves » Fri Oct 09, 2015 4:55 pm

so noisy in 1 2 3 5 r?
Check your driveshaft ujoints first Also check the driveshaft centre bearing
Check for rocks between body chassis exhaust and brakes
Take a sample of gearbox oil after a short run and after its sat for a while looking for water or shiney bits
All of the below is a guess with no chance of warrentee or comeback
Contaminated gearbox drain refill hope for the best try and drive back
Either rear ujoint Take the driveshaft out split it and reinstall the front half Select 4wd to drive home in front wheel drive (been there done that but not 500km)
Front u joint or center bearing is an issue. Your gearbox has a spline output that seals against the driveshaft Take it off and it will pump the oil out. If you can figure out a seal go for it as above but when I tried it dropped half a litre of oil in 500 metres.
Of course if you head for Haast there is only one decent hill and its not far from home by then
Sanding your knuckles before starting work can help. That way you cant skin them
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Re: Rattling Sound in all gears but 4th

Postby damo667 » Fri Oct 09, 2015 5:07 pm

Cheers Geeves
Yes 1235 and I think reverse but I'll confirm that tomorrow
I'll have a good look at the Ujoints in the morning, didn't get a chance tonight,

Weird how it doesn't do it in 4th?
vroom..._____________...........
vroom./---------|--------\.......
..&.....||______|_____O-\______....
....&...|--____---------------____--\..
........=\/-----\__________/-----\_|...
............\___/..................\___/...
User avatar
damo667
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Posts: 261
Joined: Fri May 27, 2011 12:27 pm
Age: 31
Country: new zealand
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Vehicle: 1990 Bighorn 2.8D Irmscher LWB
Roof rack,
31/10.5/15 Hankook Dynapro AT-M tyres,
6" speakers front and back, Sony head unit,
DIY Snorkel & K&N cotton filter,
Boost,EGT gauge
Adjusted boost,
Adjusted fuel,
High-flow muffler 2'5" pipe
2" suspension lift
EFS shocks

"the little rihno"

Re: Rattling Sound in all gears but 4th

Postby turnturn » Fri Oct 09, 2015 5:30 pm

Isn't 4th gear 1:1? As in the only gear where the input shaft is locked directly to the main/output shaft? Not exactly sure how this helps you in your situation, but something to consider.
What in the gearbox, when all other gears are engaged, could make a clicking sound?
Is 4th gear the only one that doesn't involve the layshaft under load?
Does the noise stay constant with road speed? Or engine speed (gearbox input shaft)?
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Re: Rattling Sound in all gears but 4th

Postby isuzurob » Fri Oct 09, 2015 5:34 pm

turn turn you are correct, i would say it has broken a tooth off the gearset on the lay shaft in the gearbox, it should be fine to drive just try not to put it under to much load in 1235 gears
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Re: Rattling Sound in all gears but 4th

Postby damo667 » Fri Oct 09, 2015 6:06 pm

It is constant with the engine speed turn turn..
the truck still running fine other then the noise,The noise is getting louder though.
So if that is the case hopefully would get me home and gearbox rebuild needed soon as..
vroom..._____________...........
vroom./---------|--------\.......
..&.....||______|_____O-\______....
....&...|--____---------------____--\..
........=\/-----\__________/-----\_|...
............\___/..................\___/...
User avatar
damo667
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Posts: 261
Joined: Fri May 27, 2011 12:27 pm
Age: 31
Country: new zealand
City: queenstown
Vehicle: 1990 Bighorn 2.8D Irmscher LWB
Roof rack,
31/10.5/15 Hankook Dynapro AT-M tyres,
6" speakers front and back, Sony head unit,
DIY Snorkel & K&N cotton filter,
Boost,EGT gauge
Adjusted boost,
Adjusted fuel,
High-flow muffler 2'5" pipe
2" suspension lift
EFS shocks

"the little rihno"

Re: Rattling Sound in all gears but 4th

Postby damo667 » Tue Oct 13, 2015 7:55 pm

800 k's after the noise started ad I've got it home drove most of that at 80-90 in 4th gear

Before i set off home I replaced to oil in the gearbox and transfer case and there was a bit of metal and even a bit of water but having said that I've seen alot worse.
Cant see and signs of wear to u joints or central bearing

The noise got louder and louder to begin with but then reached a point where it stayed constant. Its kinda the same sound as a really bad CV Joint the way it clicks..

It is present in all gears but 4th still and you can even seem to hear it slightly in neutral until you press the clutch. It is present in 2WD, 4WD and 4WD low..

It made it all that way without any 'crunching' but i parked it in my driveway which is quite steep and when I went to move it to bring in my other car it sounds way worse and sounded like its slipping from the extra load of a hill start. I had to put it in Low 4th to move it

Suppose I'd better drop the gearbox out at the weekend and have a look. Are part replaceable in the gearbox or I'm I looking at finding a second had box?

Cheers for your help guys
vroom..._____________...........
vroom./---------|--------\.......
..&.....||______|_____O-\______....
....&...|--____---------------____--\..
........=\/-----\__________/-----\_|...
............\___/..................\___/...
User avatar
damo667
Isuzu Master
 
Posts: 261
Joined: Fri May 27, 2011 12:27 pm
Age: 31
Country: new zealand
City: queenstown
Vehicle: 1990 Bighorn 2.8D Irmscher LWB
Roof rack,
31/10.5/15 Hankook Dynapro AT-M tyres,
6" speakers front and back, Sony head unit,
DIY Snorkel & K&N cotton filter,
Boost,EGT gauge
Adjusted boost,
Adjusted fuel,
High-flow muffler 2'5" pipe
2" suspension lift
EFS shocks

"the little rihno"

Re: Rattling Sound in all gears but 4th

Postby mattmannz » Wed Oct 14, 2015 3:17 am

Parts are replaceable. These also destroy the input shaft bearings.

Depending on what you want to spend it might be better to get a second hand box if you can find one that has been looked after that has less than 200ks on it
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Re: Rattling Sound in all gears but 4th

Postby isuzurob » Wed Oct 14, 2015 3:40 pm

there is a guy in chch with 2 gearboxes out of 2.8 bighorns they are on trademe
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Re: Rattling Sound in all gears but 4th

Postby damo667 » Wed Oct 14, 2015 7:12 pm

Cheers guys I'll have look at the weekend and see what the damage is and work out a plan.. is there anything I should replace on the the new box before I fit it if I go for that option?
vroom..._____________...........
vroom./---------|--------\.......
..&.....||______|_____O-\______....
....&...|--____---------------____--\..
........=\/-----\__________/-----\_|...
............\___/..................\___/...
User avatar
damo667
Isuzu Master
 
Posts: 261
Joined: Fri May 27, 2011 12:27 pm
Age: 31
Country: new zealand
City: queenstown
Vehicle: 1990 Bighorn 2.8D Irmscher LWB
Roof rack,
31/10.5/15 Hankook Dynapro AT-M tyres,
6" speakers front and back, Sony head unit,
DIY Snorkel & K&N cotton filter,
Boost,EGT gauge
Adjusted boost,
Adjusted fuel,
High-flow muffler 2'5" pipe
2" suspension lift
EFS shocks

"the little rihno"

Re: Rattling Sound in all gears but 4th

Postby damo667 » Mon Oct 19, 2015 6:00 pm

I Got the box apart tonight and found a few worn gears and bearings
I'm guessing here as I know nothing about gearboxes really, it looks to me that the bearing at the bottom of the picture on the 'lay shaft' is it?
has worn and the movement has allowed the gear behind it to get badly worn which has eventually rooted the connecting gear on the main gearset

P1040756.JPG


The larger bearing there seems ok but I guess if I was pulling it off to replace the gear I should replace that aswell
So 2 gears and 2 bearings so far.

Also on the output end I found a couple of teeth missing so should probably replace that at the same time

P1040755.JPG


I presume the gears would have to come from holden? the bearings aswell?

I'm considering taking the whole thing apart and replacing all the bearings and bushes
Probably be expensive but one less thing to worry about for a while..

Does my diagnosis sound plausible or am I barking up the wrong tree..

Cheers..
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vroom..._____________...........
vroom./---------|--------\.......
..&.....||______|_____O-\______....
....&...|--____---------------____--\..
........=\/-----\__________/-----\_|...
............\___/..................\___/...
User avatar
damo667
Isuzu Master
 
Posts: 261
Joined: Fri May 27, 2011 12:27 pm
Age: 31
Country: new zealand
City: queenstown
Vehicle: 1990 Bighorn 2.8D Irmscher LWB
Roof rack,
31/10.5/15 Hankook Dynapro AT-M tyres,
6" speakers front and back, Sony head unit,
DIY Snorkel & K&N cotton filter,
Boost,EGT gauge
Adjusted boost,
Adjusted fuel,
High-flow muffler 2'5" pipe
2" suspension lift
EFS shocks

"the little rihno"

Re: Rattling Sound in all gears but 4th

Postby pig75 » Mon Oct 19, 2015 6:42 pm

I would be looking for another box
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Re: Rattling Sound in all gears but 4th

Postby damo667 » Mon Oct 19, 2015 7:52 pm

might be easier.. just worried about inheriting more problems with a similar age box.. hard to find a low k's one..
vroom..._____________...........
vroom./---------|--------\.......
..&.....||______|_____O-\______....
....&...|--____---------------____--\..
........=\/-----\__________/-----\_|...
............\___/..................\___/...
User avatar
damo667
Isuzu Master
 
Posts: 261
Joined: Fri May 27, 2011 12:27 pm
Age: 31
Country: new zealand
City: queenstown
Vehicle: 1990 Bighorn 2.8D Irmscher LWB
Roof rack,
31/10.5/15 Hankook Dynapro AT-M tyres,
6" speakers front and back, Sony head unit,
DIY Snorkel & K&N cotton filter,
Boost,EGT gauge
Adjusted boost,
Adjusted fuel,
High-flow muffler 2'5" pipe
2" suspension lift
EFS shocks

"the little rihno"

Re: Rattling Sound in all gears but 4th

Postby turnturn » Mon Oct 19, 2015 9:18 pm

You should renew any bearings that have shared gearbox oil with those parts. All the bits of gears that have worn/broken have been splashed about in there.
My first choice at a quick fix would be to replace the complete box with a second hand one and take your chances. You can always be rebuilding that box in the background as a spare.
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Snorkle, Intercooled
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Re: Rattling Sound in all gears but 4th

Postby isuzurob » Tue Oct 20, 2015 5:10 pm

my first box did 800,000km i abused it for 120,000km till the syncros wore out in 1 and 2 gear, then put a 350,000km box in till same thing happened then fitted a low k box, they are strong gearboxes if you change the oil, just get a secondhand one
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Re: Rattling Sound in all gears but 4th

Postby damo667 » Wed Oct 21, 2015 6:32 pm

Cheers for the advice.. I might stick a second hand one on to keep moving..
Also when I took it off I noticed an oil leak from the block behind the clutch, Is it a big job to replace the seal? remove clutch and flywheel I suppose?
vroom..._____________...........
vroom./---------|--------\.......
..&.....||______|_____O-\______....
....&...|--____---------------____--\..
........=\/-----\__________/-----\_|...
............\___/..................\___/...
User avatar
damo667
Isuzu Master
 
Posts: 261
Joined: Fri May 27, 2011 12:27 pm
Age: 31
Country: new zealand
City: queenstown
Vehicle: 1990 Bighorn 2.8D Irmscher LWB
Roof rack,
31/10.5/15 Hankook Dynapro AT-M tyres,
6" speakers front and back, Sony head unit,
DIY Snorkel & K&N cotton filter,
Boost,EGT gauge
Adjusted boost,
Adjusted fuel,
High-flow muffler 2'5" pipe
2" suspension lift
EFS shocks

"the little rihno"

Re: Rattling Sound in all gears but 4th

Postby isuzurob » Thu Oct 22, 2015 3:01 pm

yes replace rear main seal while you are there, normally they leak from the corners of the sump though, also check the spigot bearing
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Re: Rattling Sound in all gears but 4th

Postby damo667 » Sun Dec 20, 2015 8:29 pm

Right finally found time to get to the gearbox...
I got a second hand one.. had a quote to replace broken parts and rebuild my old one.. I could have bought a new truck and enough fuel to do a lap of NZ for the same money!! :D

I've had a look in the new one, the input bearing has a bit of play so I'm gonna replace that, the throw out bearing is a bit rough so replace that, theres a tiny bit of play if I wiggle the inside of the spigot bearing so better replace that.
Then its just the main seal and hopefully I'm away..

There was a bit of silver sludge in the bottom of the new box but all gears look sweet, would running it full of diesel for a few k's to clean it out do any damage or should in just use oil?
I've heard of people doing this to their block before..

Cheers
vroom..._____________...........
vroom./---------|--------\.......
..&.....||______|_____O-\______....
....&...|--____---------------____--\..
........=\/-----\__________/-----\_|...
............\___/..................\___/...
User avatar
damo667
Isuzu Master
 
Posts: 261
Joined: Fri May 27, 2011 12:27 pm
Age: 31
Country: new zealand
City: queenstown
Vehicle: 1990 Bighorn 2.8D Irmscher LWB
Roof rack,
31/10.5/15 Hankook Dynapro AT-M tyres,
6" speakers front and back, Sony head unit,
DIY Snorkel & K&N cotton filter,
Boost,EGT gauge
Adjusted boost,
Adjusted fuel,
High-flow muffler 2'5" pipe
2" suspension lift
EFS shocks

"the little rihno"

Re: Rattling Sound in all gears but 4th

Postby isuzurob » Mon Dec 21, 2015 2:41 pm

Silver is just normal wear a tear, chunks its toast, just run oil in it i use 75w/85 GL4 but you can also use engine oil
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Vehicle: 1990 Isuzu Bighorn 2.8t/d, 3" extended shackles, 2" body lift, 33" silverstone extreme tyres, Front+rear bars, winch with 40m dyneex rope, 21/2 inch exhaust, lokka's front+rear, custom turbo, emissions removed, injector pump modified and more

Re: Rattling Sound in all gears but 4th

Postby damo667 » Mon Dec 21, 2015 6:14 pm

Cheers Rob
just struggling to get the spigot out without a puller might have to borrow one..
Any tips on the main seal? does it just pop out?

Cheers
vroom..._____________...........
vroom./---------|--------\.......
..&.....||______|_____O-\______....
....&...|--____---------------____--\..
........=\/-----\__________/-----\_|...
............\___/..................\___/...
User avatar
damo667
Isuzu Master
 
Posts: 261
Joined: Fri May 27, 2011 12:27 pm
Age: 31
Country: new zealand
City: queenstown
Vehicle: 1990 Bighorn 2.8D Irmscher LWB
Roof rack,
31/10.5/15 Hankook Dynapro AT-M tyres,
6" speakers front and back, Sony head unit,
DIY Snorkel & K&N cotton filter,
Boost,EGT gauge
Adjusted boost,
Adjusted fuel,
High-flow muffler 2'5" pipe
2" suspension lift
EFS shocks

"the little rihno"

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