18/11/08 - Transfer Box Problems

I have had some problems recently. Everytime I release the clutch pedal when under load (ie. Steep hill or obstruction whilst off-roading/trialing) I got a loud BRRRT! noise from somewhere under the car.

Looking around the web I decided that the most likely problem is a slipping transfer box chain.  This is because too many people have reported problems with the chain in the past and the previous owner of mine was doing something with the Transfer Box before I bought it and my personal feeling is that the special Low Ratio Jimny Gearset is make the problem worse.

The first two pictures below show the slack in the chain (although this is made worse by the removal of the case cover as the gearshafts can move a little bit)

Here are some metal particles lining the case :(

Here is a close up of the smaller special Low Ratio Jimny Gearset Gear

And the large one

And the other side of the large one

Close up

And the chain

Currently I have put another completely different transfer box on as a replacement chain is £300.

The other transfer box is fitted with standard gearing and the car is wonderfully quiet, there is not loud noises on clutch take up and there is NO whine from the Transfer Box. So miy personal feeling is that something in the pictures above was causing me real problems.