Knocking Noise

[Bodgit-fixit-run]

My 54 plate diesel Rav 4 has just started making a knocking noise two days ago.

I have read up on the DMF info and am worried it might be this however before I go into panic mode re cost. I thought I would check this out.

The sound seems to be coming from the transmission side and is there until I start to move the car. Regardless of clutch position. However when traveling it seems to disappear until I slow down at light etc when it is considerably worse. I have it recorded if anyone wants to hear it. (Just in case).

I'm waiting for the haynes manual to come out and am prepared to change it myself if necessary.

I've done the last two services myself and am about to change to timing belt which is overdue. Car has done just over 67K.

All suggestions greatly received.

[bothwell_buyer]

I had the same with my landrover.

I'm waiting for a miracle!!

Good luck in getting a solution.

[anchorman]

My 54 plate diesel Rav 4 has just started making a knocking noise two days ago.

I have read up on the DMF info and am worried it might be this however before I go into panic mode re cost. I thought I would check this out.

The sound seems to be coming from the transmission side and is there until I start to move the car. Regardless of clutch position. However when traveling it seems to disappear until I slow down at light etc when it is considerably worse. I have it recorded if anyone wants to hear it. (Just in case).

I'm waiting for the haynes manual to come out and am prepared to change it myself if necessary.

I've done the last two services myself and am about to change to timing belt which is overdue. Car has done just over 67K.

All suggestions greatly received.

I'm really impressed by anyone who is willing to have a go. I can probably email all the pages of the manual you need if you pm me with your email address.

What happens if you press the clutch when stationary?

Can you post a link to your recording?

Oh and welcome to the club.

[Bodgit-fixit-run]

Forgot to say. The sound is not rhythmic as in it doesn't increase with engine speed.

Did have a fault code pop up a few weeks ago regarding a possible turbo fault number p1215 that was corrected by just canceling the code. It's not come back since. I don't think they are connected.

Ta Malc.

[Bodgit-fixit-run]

Thanks for this Anchorman

I've sent you the link for the sound file and my email address.

It doesn't seem to make any difference when the clutch is pressed or not the noise is the same.

Thanks for the welcome.

[local hero]

Thanks for this Anchorman

I've sent you the link for the sound file and my email address.

It doesn't seem to make any difference when the clutch is pressed or not the noise is the same.

Thanks for the welcome.

Hi + welcome Bodgit, I am not very mechanical so can,t advise on your problem, however i do believe that MrT extended the warranty on DMFs for 5 yrs or 100k miles, which your vehicle is still inside, I may be wrong (It has been known) but sure someone else will advise

[Bodgit-fixit-run]

Hi Local Hero

I think it was 60k warranty which mine is outside of. Could someone confirm for me please.

[anchorman]

You can ask but I don't think they will underwrite it at that mileage.

email sent.

Cheers

[Bodgit-fixit-run]

Anchorman

Thank you so much for the email and stuff. It's really helpful. Particularly the warning.

Looks like my spare time is going to be taken up for the next few weekends then.

Just go the find the dosh first.

Fortunately I quite like DIY and have built up a few engines in my time. Never tackled a diesel though.

Ironically when I got the car from new. I opened the bonnet and closed it again quickly.

I have read somewhere about having to change the ECU is this right or am I imagining it? I'm hoping for the latter.

I was given last year an old 1990 corolla petrol automatic. which has done about 170k and still going well. Had to do a load of welding and change a drive shaft but that's all really. Sad innit.

Like many others I luv me Rav.

[chatman]

Anchorman

Thank you so much for the email and stuff. It's really helpful. Particularly the warning.

Looks like my spare time is going to be taken up for the next few weekends then.

Just go the find the dosh first.

Fortunately I quite like DIY and have built up a few engines in my time. Never tackled a diesel though.

Ironically when I got the car from new. I opened the bonnet and closed it again quickly.

I have read somewhere about having to change the ECU is this right or am I imagining it? I'm hoping for the latter.

I was given last year an old 1990 corolla petrol automatic. which has done about 170k and still going well. Had to do a load of welding and change a drive shaft but that's all really. Sad innit.

Like many others I luv me Rav.

You and Anchorman are going to have a very good relationship.....and we'll all going to love reading the threads........... you could even join our Ocean 13 1/2 team......

It's a big job if this turns out to be the DMF..best get a help lifting the gearbox and transmision, dont want to e dropping those.. The ecu was changed on some vehicles but not all....

[bothwell_buyer]

well ma man - aifter ma own hairt

chuck the engine and implant a 3SGTE - I can help ye oot

Then get ready for the ride o yer life!

[Bodgit-fixit-run]

Anchorman

Thank you so much for the email and stuff. It's really helpful. Particularly the warning.

Looks like my spare time is going to be taken up for the next few weekends then.

Just go the find the dosh first.

Fortunately I quite like DIY and have built up a few engines in my time. Never tackled a diesel though.

Ironically when I got the car from new. I opened the bonnet and closed it again quickly.

I have read somewhere about having to change the ECU is this right or am I imagining it? I'm hoping for the latter.

I was given last year an old 1990 corolla petrol automatic. which has done about 170k and still going well. Had to do a load of welding and change a drive shaft but that's all really. Sad innit.

Like many others I luv me Rav.

You and Anchorman are going to have a very good relationship.....and we'll all going to love reading the threads........... you could even join our Ocean 13 1/2 team......

It's a big job if this turns out to be the DMF..best get a help lifting the gearbox and transmision, dont want to e dropping those.. The ecu was changed on some vehicles but not all....

Tell me more about Ocean 13 1/2 sound a bit of a giggle.

Starting to make up some engine supports this pm. It's amazing what a severe lack of dosh can induce.

If anyone's interested here is the dreaded noise. Knocking DMF

[chatman]

Starting to make up some engine supports this pm. It's amazing what a severe lack of dosh can induce.

If anyone's interested here is the dreaded noise. Knocking DMF

Blimey....Sounds like you pulled up next to blacksmith & he was knocking out some iron gate.... ;) ;) ;) ;) Also when did the tractor pull up next to you as well....just when you where recording the sound as well..........

When my DMF went, it had a more metallic knocking noise...could have been the bits it disintegrated out of the DMF though....Unsure of your noise though ;) .....What's Dr Anchorman prescribed

Tell me more about Ocean 13 1/2 sound a bit of a giggle.

Well this is Me (on left) then Local Hero and then Anchorman....We where waiting around at last motor show..... :unsure:

[anchorman]

I suggested it he didn't run it any more than absolutely necessary!

[Bodgit-fixit-run]

That means I must be the guy in the background.

I've not run it since cos the local farmer came round just after to see I he could borrow my traction engine to finish ploughing his field.

[bothwell_buyer]

That means I must be the guy in the background.

I've not run it since cos the local farmer came round just after to see I he could borrow my traction engine to finish ploughing his field.

wow - you've got a traction engine?????!!!!

[Bodgit-fixit-run]

That means I must be the guy in the background.

I've not run it since cos the local farmer came round just after to see I he could borrow my traction engine to finish ploughing his field.

wow - you've got a traction engine?????!!!!

Almost.

Just finished my rough and ready support beam. So could this now be a beam engine ;)

Gonna start the strip down on Wednesday when I actually have a day off.

I am actually building a model live steam engine. Guess thats on hold for a while. (Again).

[Bodgit-fixit-run]

That means I must be the guy in the background.

I've not run it since cos the local farmer came round just after to see I he could borrow my traction engine to finish ploughing his field.

wow - you've got a traction engine?????!!!!

Almost.

Just finished my rough and ready support beam. So could this now be a beam engine ;)

Gonna start the strip down on Wednesday when I actually have a day off.

I am actually building a model live steam engine. Guess thats on hold for a while. (Again).

[chatman]

Must be eager bodgit...you posted twice....

When you do get round to doing, may be worth while photographing the sequence of events in getting to the DMF...we have pictures of the DMF (well mine when it was changed) but not the actual RAV in bits...only if your willing too.............

[Bodgit-fixit-run]

Must be eager bodgit...you posted twice....

When you do get round to doing, may be worth while photographing the sequence of events in getting to the DMF...we have pictures of the DMF (well mine when it was changed) but not the actual RAV in bits...only if your willing too.............

Yeh don't know how that happened. Posting twice.

Will certainly take photos of the job as I go along. Taht way if I end up in deep doo doo then you lot can help me out.

Had one quote today for the kit or not Clutch 120 + Vat DMF 700 Plus vat. Have challenged that and am waiting for the shop to get back to me. They weren't aware of the Valeo 4 part kit (apparantly). They asked me for the part number. Valeo don't supply direct.

[Bodgit-fixit-run]

Hi Local Hero

I think it was 60k warranty which mine is outside of. Could someone confirm for me please.

Hi again Local Hero

In terms of the warranty. It was extended in 2002 to cover the original DMF but only for 5 years. so this expired in 2007. Mr T apparently modified the MDF but by the sounds of it without making much impact on the problem. To be honest I had never heard of an DMF before I had the RAV. I do tow a caravan with it a couple or three times a year though so that can put some strain on the drivechain I guess. I did once get stuck part way up a hill in a 1600 Cavalier that sent lots of smoke blowing around the road. The reason I got stuck was someone in front stopped their horsebox on a 1 in 4 hill. I then couldn't move off again. Some nice bloke in a lorry cam to the rescue and pulled the car and van up to top of the hill. Greenflag weren't interested and told me to burn the clutch out first and then they would come and recover me. Guess who I'm not with anymore.

[Bodgit-fixit-run]

Right then

I've made a start. A day early but that's OK.

Here follows the amateur's guide to taking a car to bits.

The car is now up in the air. Safely!

Wheels are off as are the under panels.

Removed

Intercooler; Engine cover; air filter & housing; fuel pump. (Tip stick a couple of bolts into the ends of the now exposed fuel lines to stop crap getting in).

Did well really only lost one bolt so far. Found it after an about half an hour behind a windscreen wiper. Don't ask how.

One question though.

Any reason why I would be showing oil on area marked in RED. Knowing very little about diesels I'm assuming this must be an injector. Could it be blowing a little? There seems to be a small amount of white powder around the others. Is this something to be concerned about?

NEWSFLASH

THE UK HAYNES MANUAL IS NOW AVAILABLE. Mine arrives tomorrow.

[anchorman]

There is a rubber seal where the pipe connection to the injector emerges through the cam cover. As long as it isn't bad don't worry about it. If it starts to leak oil rather than just damp, Kingo will send you a set if you contact him.

The white stuff is just oxidation of the aluminium and is of no concern.

[Bodgit-fixit-run]

Thanks for that Anchorman. Duly reassured.

Just getting ready to remove driveshafts etc. Any tips. I assume they are the same as other shafts and just drift free.

Those gear selector clips for the cables are a bugger aren't they? One drew blood as it eventually came free. :(

Still I got the s**t back.

[anchorman]

Just the same as most other FWDs really. I undo the nut with the wheel on the deck then after detaching the lower suspension use a copper or brass drift (something with a soft face - even hardwood works to start it) to knock the shaft through. Push the shaft while turning the hub to allow it room to come out at the back. Once it is hanging free use a big screwdriver to prize the shaft out of the gearbox. There is only a snap ring to hold it in.

I will be away for a few days while I visit Ireland then Germany (RAV all tanked up!) so watch the following when putting the shafts back.

Sometimes the spring comes out of the seal where the shaft goes into the diff casing. If it does, carefully feed it back in. Providing the seal wasn't leaking before it won't leak as long as the spring is in place. If there is any damage or leaking change them anyway (left and right). Lightly oil the seal boss on the inner joint and feed it in, twisting to engage the splines. Push it fully home and make sure it held in with the snap ring. If it does not engage get a piece of soft wood and tap against the inner joint gaiter but not so hard as to damage it. When it won't pull out by hand it is engaged.

At the outer end clean up the splines and give them a squirt with WD40. Look through the hub to make sure everything is in line (the hub and bearings can drop so just ease them into position as you feed the CV joint through). When it is far enough through to get the nut on, do so and run the nut up until you can get the washer on then take the nut off and put the washer on. That nut goes tight as indicated in the instructions I sent you so leave it until the wheel is back on the ground but don't forget. Put a not on the dash to remind you!

You're on your own for a bit as far as I am concerned but somebody else will help you if you get stuck!!! I think it will all make sense anyway. Don't forget to photograph as much as you can and we can get it pinned as a maintenance tip.

Those clips on the cables are fun! I usually get a screwdriver between the bent flange at the top of the clip and the cable then turn it through 90 degrees to ease it out. They can fly as well!!!