[zukenutter]

Also, with the rear shaft off you could run through the gears while stationary, may help in better pinpointing the origin of the noise although it won't be under load.

[twitch911]

try checking out the rear gearbox mount i had a problem like that it kinda sounded like a mud flap rubbing underneath took me a while to find the problem it was the middle bolt it had rattled out on its own try lifting the gearbox

[Mike57]

ZN, now you have added another dimension to this one! I have manual hubs now so the hubs have not been engaging by them selves (in fact I had the opposite problem) but I have done a bit of on road driving with them engaged and in 2WD. I don't see how that would have done any damage though.

Anyway I will remove the rear shaft and see where this leads. Thanks for the tips. Being time poor this is going to take me a few weekends before I can get to it.

[Scales]

No i think ZN is talking about just having it in 2wd and putting drive to the case whilst STATIONARY. IE isolating the shaft. But yeah as he said... zero load, so you wont have any slipping.

locked in 2wd wont hurt shit.

[christover1]

We can to get together, take turns driving, feeling, listening etc if needed.

Running with all wheels off ground, listening with a long wood pole, or pipe can isolate noises not normally heard.
Particularly rattles of chains, bearings eyc, by touching area around them.

I need to do this for any chance of hearing anyway

[Scales]

hate to sound like broken record, but listening etc is just prolonging things, theres nothing else under the car in that region.
If you think its shaft, check it.
the only real way to check the box is to split it. Do you have the workshop manual mike? I just had a read it mentions the symptoms and possibilities. fix included replacing chain, gears and "collar" if the teeth are chamfered.

[zukenutter]

Make sure you let us know the outcome Mike. Definitely won't be your hubs engaging by themselves.




Why am I not getting email notifications, very frustrating

[Mike57]

I did check the gearbox mount but I will check again. I am going to go systematically though the possible causes and want to eliminate the rear drive shatf and differential first by removing the shaft. I have the CD manual which I think you sent to me Scales. I did take a look but once I narrow this down to the Transfer case it will come out for an inspection. I will keep you all informed as I go.

[Scales]

Oh yeah forgot I hooked you up with that.
Good luck mate, I feel for you, its a shit situation and I hated my rig pretty hard afterwards.

[MikeyS]

Hi Mike i know im no expert or anything but i wouldnt say it is the CV thingy having dirt or anything in it because for the last 4 weeks my CV thingy didn't have the plastic boot inside that joint and i have been through a shit ton of mud water and slush and i have had no problems like that or noises.

[kyzermattingley]

Definitely the transfer case, mine is doing it ATM, at first it only did it in 4wd low, then 4wd high, now it's doing it in 2wd 1st gear, I had the same problem when I used to run 33 on a Feroza, definitely the transfer

Kyzer

[Mike57]

Kyzer - Did you fix the problem. Was it just a strectched chain or did you need to replace any other components. My transfer has always been very noisy (whining) so I am wondering if there is a need to replace anything else while it is apart? It seems there are lots of 4WD's that use a chain drive including the wrangler and this is a commopn problem from looking at Youtube. I am now pretty sure it is the transfer chain as well.

Mike

[kyzermattingley]

Mike57 wrote:

Kyzer - Did you fix the problem. Was it just a strectched chain or did you need to replace any other components. My transfer has always been very noisy (whining) so I am wondering if there is a need to replace anything else while it is apart? It seems there are lots of 4WD's that use a chain drive including the wrangler and this is a commopn problem from looking at Youtube. I am now pretty sure it is the transfer chain as well.

Mike

Mine originally started as a whine, and just progressed, I'm about to pull it out and fit a Sierra transfer case

Kyzer

[kyzermattingley]

I'll try and post pics of the whole lot in the next few days

Kyzer

[Bugsta]

Slipping transfer chain. An adjustable chain guide here would be a good retrofit fix.

[Mike57]

Got a replacement transfer case fitted this week. The whining noise has gone and I also took it to my test hill and no sign of a slipping chain. So it was clearly a problem in the transfer case. Strange thing is that now the old case is out I was expecting to find a fair amount of slop between the input and output shafts but there really isn't much, not much more than on the good case. Either it does not take much stretching of the chain to allow it to slip on the cogs or there is another problem. I suspect it just doesn't take much stretching for this problem to occur.

By the way I took it down to this guy http://www.cammoffroad.com.au/, Cameron. His price was very fair and he did a thorough job. A bit of a drive from Melbourne but it was worth it for good service.

[superduki]

Mike57 wrote:

Got a replacement transfer case fitted this week. thing is that now the old case is out I was expecting to find a fair amount of slop between the input and output shafts but there really isn't much, not much more than on the good case. Either it does not take much .

Whilst the chain tension probably plays some roll in the centralising of everything, the tension of the flanges should be controlled by case shim adjustment and tension on the flange nuts. I'd be surprised if you would notice any fault externally.

I have ZN old vvt transfer in my partners Jim, as hers had a monster whine and wouldn't select 4wd at all. Turned out the electric motor actuator had been swamped at some stage (we bought the car with the said fault) and had corroded. Talking to the lead Suzuki mechanic locally he was telling me that he had seen chains stretch in them, and apparently the whine is fairly consistent, they have had a few return under warranty, and fitting new gearsets to quieten them down as he reckoned the problem was 'ovalised' cutting of the gears, causing a whine.

With her old case I've been umming and ahhing about stripping it and trialing a set of 20% reduction gears in it, fit a new electric motor and re-use it. The whine shouldn't get louder if looked after, as I'm not prepared to buy a new gearset for it. She is currently running 215's, but I want to add another 25mm to it and sneak 225 or possibly 235's on it. (currently at 2' lift), as we drive a bit of rock in Tas, and I find the gearing putrid in it's current form.

Good to hear a good outcome mate!

Cheers, Superduki.

[Mike57]

Thanks Superduki. I plan to strip the old case down and try and work out what was going on. Might be more of a summer time job when I can get things done in the evening. Way too cold at the moment out in the garage at night. I will post up some photos when I get to it.

Mike