02 4x4 problem +recon transfer box

Ok brought recon transfer box , got Ed the machanic to fit it ,phone call late.its the same as one taken out but making a lot of noise.see 02 4x4 problem (.HELP ANY ONE PLEASE)

Take it back for a refund if it is noisy.
The jimny 'box is chain drive and very quiet in high. (The oil level is correct?)
They whine in low because of the gearing system used.

Don't know why you bought a new 'box, reading your other thread I don't think you found the problem.

Anyway, with the original 'box on the table:

In 2wd, turn the top (input) flange. The rear flange should rotate (good) Hold the rear flange in one hand, twist the front flange, it should be free to turn. (good)

In 4wd h the front and rear flanges are locked together (good) turn and turn and turn the top flange, the lower flanges rotate and rotate and rotate (good)

In 4wd low the front and rear flanges are locked together (good) turn and turn and turn the top flange, the lower flanges rotate and rotate and rotate at a lower speed (good)

If it fails one of these tests it is broken.


Refit transfer box.

engage 4wd with engine running. Listen for clack clack from hubs, and green 4wd light. (good)
Jack up one side of car so same front and rear wheel is off the floor. Chock wheels on floor so it cant roll away. release hand brake.
Rotate front wheel by hand forwards to take up any slack, the rear will start to turn. Mark the lowest point of each tyre with chalk.
Rotate front tyre the same way a few turns, see if the mark on the rear tyre is following exactly. (I bet it wont) Post back what happens to the rear chalk mark after 2 turns of the front wheel.

Hi all done as you said. you won the bet.when turning front wheel two turns. back wheel out by not quite a Quarter.cheers???????

Now you are in trouble.

One of the differentials has been replaced with the wrong ratio.
1/4 turn out in 2 turns is a lot, nearly 10%

The document in the info pages reckons 3.909:1 for a manual 4.090:1 for an auto and 4.300:1 for a late model manual.

I would suggest you have an early and a late diff fitted front and back. I didn't think the late diff would fit as the halfshaft spline count is different, so you may have a later axle fitted at one end, likely the front is wrong, as some people change the axle rather than sort out the kingpins.

If I'm right, the back wheel mark is getting in front of the front wheel one.

That was my diagnosis on the original thread about this!

Its good that youve found the problem - and its not an expensive fix.

Si

So it was Simon, well done

(Have to admit I only skim read the thread)

Bought a Jeep Cherokee once, stuck it in 4wd on tarmac and drove forwards a bit to test the 4wd (not sure what that was for really, but I was only in my 20s)
Couldn't get it out again.
Reversed back to the same place, still wouldn't come out.
Jacked up a front wheel and it sprang round nearly 1/4 turn.

Had bigger tyres on the back than the front, and a 4.2 litre engine to scuff them round..