Feroza transfer case issues

[De-lux]

Hey all,

Got some q's for the Feroza guru's out there - regarding my missus's little beast.

Background:

I bought this 88 Feroza for the missus - it is clean, has high km's (300,000km's) but came with (what I assume is ) a newer model 1.6 EFI motor, extractors, exhaust, pod air filter. The engine has been strong and always pulled hard, and hasn't been too much trouble.

Here in lies the problem - a few months ago, a loud noise was coming from the transfer case. It was a loud mouning / grinding / howling noise. After some guess and check, I dumped the oil in the tcase - sure enough, only about 300ml comes out (should be 1400ml). I put fresh gear oil and and viola - she ran beautifully again.

Fast forward a month later, and BAM! the noise comes back. This time, when it started making the noise, we were at the Gold Coast (we live in Brisbane).. I made the potentially foolish decision to press on to brissy, and I vowed to fix it when i got home. Sure enough, half way home (40kms to go) the tcase makes a god aweful noise, I depress clutch, and the car jerks abruptly to a halt. We park up, call a mate with a car trailer and tow her home :(

ANYWAY, back home, only a week ago, I'm under the feroza sussing out what's gone wrong - I suspect the problem is previous owner used a galvanised big arsed (wood construction type) washer instead of a proper fabric sump washer. This wouldn't have sealed correctly I'm assuming, which would have led to the oil slowly leaking out.

So this afternoon I'm back under there, putting on the fresh sump plug and new proper washer, and bazinga - a 20c sized section of the cast alloy tcase housing snaps off still attached to my plug. Epic bummer, now I assume the entire housing is FUBAR.

So the reason for the background story - I suspect something inside the transfer is cactus anyway (from running it dry) but now there is a god almighty hole in the casing.

What should I expect to pay for a new (second hand from wreckers etc) tcase to suit an EFI feroza 1.6L motor adn 5 speed manual box?
Is there any difference in transfer cases?
How hard will this be to change myself?

[Goatse.AJ]

IF you can get a second hand (stuffed) gearbox, chances are the transfer will be OK. I'd explore that option first, as the Tranny case is easy to pull off the back of the gearbox and swap onto your existing one. = MUCH cheaper.

[Percy]

You will be looking at about 300 or less for a transfer and gearbox. You can easily pull off the old transfer and replace only about 10? bolts I think.

[De-lux]

Yeah sorry, I should have clarified - the gear box is in fine condition, I won't change that.

Only looking to swap tcases.

[De-lux]

Here's a stupid question for you - do I have to disconnect front and rear driveshafts to take off the tcase?

[Goatse.AJ]

YES you have to disconnect the shafts.

Best option is to drain the gearbox and tranny case, drop them out of the vehicle, then split them. A pretty easy job, usually no more than 3 - 4 hours.

The reason I suggested getting a stuffed gearbox is that the tranny case doesn't usually give as many problems as the gearbox, so you should be able to find a stuffed gearbox cheaply that still has a decent tranny case attached.

[De-lux]

ok so i've rang around some wreckers, I can get one from a wreckers in Coffs Harbour for $100. I'm guessing this would cost me about another $100 in delivery so I might try to look at more wreckers closer to home.

Hmmm... I hope this doesn't end up being a huge mission

[Goatse.AJ]

So long as you can get a box, it should be pretty straight forward. I had mine out twice last year, once to replace the gearbox and then to replace a grenaded clutch.

It helps if you have a nice loooong socket extension, even easier with air tools.

[Percy]

Plenty of wreckers around in Brisbane which should have them could try Daihatsu wreckers at Archerfield, usually reasonably priced 38752555.

[De-lux]

I've rang around to a few (inc Diahatsu at Archerfield) and they all only want to sell gbox and tcase together.

There is another forum member selling a Rocky tcase for $100... does anyone know if this'll fit?

[tehekho]

I Don't think the rocky Transfer Case will fit your Feroza. If you get a definate 'not compatible' could you let me know who is selling it as I'm interested in one...

[De-lux]

Well to be honest I doubt it will fit, so you may as well have it. It's being sold be Simo (check the classifieds)

[V.W.Dave]

Here's a stupid question for you - do I have to disconnect front and rear driveshafts to take off the tcase?

WOW really..... Did you actualy ask this??? were you drinking???