Samurai Transfer box with 4.16 T-Case Noisy

Hello dear friends.
I have a 2009 Jimny with 235.75.15 tyres and a samurai transfer case with 4.16 gear reduction kit which is awfully noisy.
I know this is usual for a samurai transfer case but it drives me crazy, and about to go back to the original transfer case (which will be a shame as the car performs sooo well on rocks right now).

Did anyone find a solution for the horrible noise?

Please let me know.
Thank you
Guy

You could try to find some rubber bonded mounts similar to the originals but in my experience this is not easy as they need to be small so as to not push the transfer box up so as it touches the shell. There also needs to be a bit of spare room to allow for movement in the bush, given it's rubber.

The bolt all the way through heavy duty mounts link the box and the chassis by the bolt whereas the rubber bonded mounts have rubber between the chassis and box damps the noise.

The noise is caused by there being new and old gears being used and they have different wear patterns, assuming you have no worn bearings.

I did some research a while ago and drew a blank, tried KAP heavy duty SJ mounts but they pushed it up too high and I fear the extra torque the box makes will chew Suzuki OE Jimny mounts up in no time.

Kirkynut

don't u think some kind of insulation in the hole where the gearshift is will help the problem?

something like this?
www.dynamat.com/products_car_audio_dynaliner.html

I doubt it would do too much to be honest as the noise is transmitted through the chassis and the body but it might dumb some of it down a little.

Kirkynut