Rough rattle noise in low gears, how worried should I be!?

[Jazza]

I have been working on my 1995 413 Samurai for the last couple of months and have only just got it on the road for the first time today!

This is the first 4x4 I have owned, so I'm an absolute newbie to all this and have no idea about them...
I have tried to look through the forums for similar symptoms to what I am having but I am still unsure.

Okay so my symptoms are:

When the engine is running in neutral & whilst revving it - Sounds Perfect
When driving in 1st gear - Sounds Rough & Rattles
When driving in 2nd gear - Sounds Rough & Rattles
When driving in 3rd gear - Sounds Rough & Rattles
When driving in 4th gear - Sounds Perfect
When driving in 5th gear - Don't know, as I have 31" tyres and not been able to get there!

Is it my transfer box?

Thank you in advance everyone!

[ScottieJ]

Sounds like a bearing in the gearbox, 4th is 1:1 so straight through and this could stop the suspect bearing(s) from spinning

[Jazza]

Sounds expensive I was kinda hoping it was the Transfer box, as it would be easier to replace!

Is it safe to drive for now (obviously not holding you to anything!)?

I think this is going to be out of my skill range, as I only know basic mechanics...

Do you think it will be cheaper to repair or replace?


Thank you for your help!

[andyrew]

Cheaper to replace but finding a proven good
Box is the issue. The gear boxs can be bought for around
30 quid most of the time so its punt money really but its the wasted hours changing the box again if its a dud, thats the annoying bit.

Gearbox change is dead easy on these tho.

When i done my first sj gearbox i had the essentials to hand.

Beer
A good mate to chat to and assist when needed.
Bacon sarnies.

Plus just a basic socket set and some spanners

If the gearbox isnt making the zook lurch or jump about i wouldnt worry to much about driving it. My kjas gearbox sounded like
A food blender in 1st 3rd and 5th. And never caused a problem.

This tho is coming from a guy whos sami gearbox is on about 140k plus and when its in neutral it trys to pull away

[dan_2k_uk]

This tho is coming from a guy whos sami gearbox is on about 140k plus and when its in neutral it trys to pull away

My current one has started doing this when I'm in low box.

My last one actually sounded like a cement mixer full of house bricks and the truck was still driving.

I guess if reliability isn't a concern or its not your main vehicle then get every last bit of life out of it and run to destruction.

I've been planning on rebuilding my old gearbox for a while as its one thing I've never done but the rebuild kits or even just individual bearings are quite expensive for the risk involved.

[RickUK]

I always have found that if a new noise starts appearing on my Vitara,if i turn the radio up louder the noise goes away like magic,works every time for me

[Jazza]

Thank you for all your help guys, this has put my mind at rest a bit.

I think I will try to find a decent second hand box & one of those rare SJ410 Transfer box's, service them both and attempt to slap them on myself.

In the meantime, I think turning up the radio is the best bet


So if anyone has a decent Samurai gearbox or SJ410 Transfer box they want to sell, I am all ears