Knocking in 4wd

[FROZY]

Just wondering if anyone can sugest what the knocking noise i get is when i put her in 4wd. I had a mate look at the drive shaft while going along slowly and it jolts every time the knock sound is heard. The uni joints apear to be ok but its hard to tell where the noise is coming from exactly.

[RockyF75]

Is it as you go in 4wd or as you change into 4wd? You said ur mate was under the car and had a look and the shaft jolts... the whole drive shaft, or the part that runs the rear wheels, or the one that runs the front? (i wish i new the fancy names for these things ). In my rocky i had a problem with something in the gearbox that caused the driveshatft to kick back and forth (back when accelerating, forward when decel), wich inturn damaged many of the bearings and stuff in there.

[FROZY]

The jolting happens on the front drive shaft but only while in 4wd with the hubs locked. It pretty much occurs under load or just if i give it stick. I jacked the front of the car up and gave the front drive shaft a jiggle but there was no movement other than rotation. I couln't get it to make the noise while it was jacked up only while under load.

Its a bit of a tricky one i don't think its a uni joint but dont know where to look next. Maybe a mechanic is the go at least to diagnose the problem.

[BundyRumandCoke]

Does the Feroza have splash guards around the engine, like the Rockys? If so, check these out. I had a similar problem, loud knocking on suspension compression in 4wd. It turned out the mount on the splash guard had fatigued through, and the guard had dropped enough that when the tailshaft rose on suspension compression, guard touched tailshaft yoke. It took me ages to find, and the splash guard didnt even make it to heaven when I found it.
Otherwise, look for missing paint or shiney surfaces on the tailshaft. This may give you a clue. Or else a broken mount, or partialy siezed U joint.

[FROZY]

I Got the vehicle checked out by a mechanic yesterday. They drained the oil and found nothing out of the usual just small filings in the transfer case and nothing in the diff. Then they disingaged the hubs and tried holding the tail shaft to put some pressure on the transfer case while running on the hoist. Then they discovered that the noise was coming from inside the transfer case, they said it was probably teeth missing.
So i will be up for replacing the transfer case or reconditioning it.

Does anyone have any thoughts on this?

[murcod]

The feroza transfer case uses a chain drive- not gear to gear drive like the gearbox. I don't know much about transfer cases, but given it's chain driven, "teeth missing"sounds a bit suss to me?

[SimplyPV]

The feroza transfer case uses a chain drive- not gear to gear drive like the gearbox. I don't know much about transfer cases, but given it's chain driven, "teeth missing"sounds a bit suss to me?

it may not be gear to gear, but its gear to chain to gear. so there still is teeth driving the chain itself. (like a bike) i'm surprised all they found were small fillings. should of found more i think. only way to find out is to crack it open and take a peek inside.

i assume it still works? if it does, dont fix it until it needs to be fixed...

[FROZY]

It still works but its got a terrible knocking noise constantly while under load.

Yeah they said the next step is to look inside but it was going to cost me though......around $600 in labour to open it up, remove and then posible parts to be fitted. Looking at anything up to a grand with these guys.
I will ring around and get some quotes from specialist gearbox mechanics to see if i can get it done any cheaper.

I have found a second hand gearbox and transfer case the guy said that the gearbox is stuffed but the transfer case worked fine at the time the gearbox packed up. I thought i might be able to replace it myself...... Not so, i looked at the workshop manual and it doesn't look too easy at all. The whole gearbox has to be removed and then the transfer can be changed but it looks pretty technical to me, definitely out of my ball park.

Can anyone recomend somebody reputable in perth?

[murcod]

The feroza transfer case uses a chain drive- not gear to gear drive like the gearbox. I don't know much about transfer cases, but given it's chain driven, "teeth missing"sounds a bit suss to me?

it may not be gear to gear, but its gear to chain to gear. so there still is teeth driving the chain itself. (like a bike) i'm surprised all they found were small fillings. should of found more i think. only way to find out is to crack it open and take a peek inside.

i assume it still works? if it does, dont fix it until it needs to be fixed...

Chains wrap around the drive gears - so a single tooth missing shouldn't be as critical as a gear-> gear situation.

[FROZY]

Yeah i think its a bit suss too. More likely to be some sort of bearing or something just guessing like the mechanic was though.

Will ring around and get some gearbox specialists to listen to the noise and see what they say.

[SimplyPV]

or just drop the tranny, crack it open, and see whats inside. stop guessing and find out.then go from there. you could do it all in one day. after you take a peek, put it back in and away you go to get what you need.

[FROZY]

Does anyone know if narrow track and wide track ferozas have the same gearbox and transfer case?

[FROZY]

Gday all.

Just got back from a test drive in some sand. I found a second hand transfer case and had it fitted by a gearbox shop. $275 labour and $80 for the second hand transfer case.
Pretty stoked hey it runs really well in all gears.
After a while i will be looking at replacing the oil in both the gearbox and transfer case with some top notch stuff, anyone got any recomendations on good gear oil?

[murcod]

Redline oils are fantastic. www.redlineoil.com.au I run it in my Feroza and the gearbox is so much nicer to shift.