Jimny Gen3 87/17% TG-kit, low geared transfer case, push button.

Lambert wrote:

Just out of interest how cataclysmicly loud are these gears? Obviously enough for you to think it needed looking at but annoying, unpleasant or painful? I ask as I keep getting drawn to their 15/104 set for the automatic which I want with 235s to take the top end out the autos gearing.

Seriously considering taking the spare transfer box with me to Denmark. That is how painful it is. 
I cut a trip short last year after doing a day of exploring in the mountains going up too many steep hills. 
As everything else looks OK inside I think the high range sprockets for the chain are too worn. 

But then again the noise has been there since i put the gears in it. It just has slowly gotten worse so might not be so dramatic, no problem until the chain start to slip wich i felt happen with the last chain that was in it and well stretched.
Worn spockets make the chain stretch more easy too.

My transfer case had maybe 100000km on it when I put the gears in. Now approx 150000km so there is still a lot of miles in a low range kit.


Not sure what to do next though. Guess i 'll just drive until it blows, and see then what the next chapter is.
Buy a 2004 jimny maybe so I can go for the 4.16 SJ transfer with no chain.
Or maybe dump the gen3 all together and finish building up my lwb SJ416 on 31's. 

  

So potentially what you are saying is that if one were to look at the regear as an opportunity to build a fully new box into a used case it could be entirely reasonable for a good number of miles/years?

Yes, i would do it again.
The added drivability with 235's and the lots of fun i had with the very low low gear ratio make it still worth it.

Even though my case was worn and still is, I am still going at 50000km and will continue. And I have not been nice to it. And while the case still goes, i have broken a diff and a gearbox from the added power.

It would be smart to start with a low milage donor case, change any bearings with play and, change the chain when doing the regear.
But i got 50000km saying it is not nescessary.

Yesterday I did a stupid thing and backed up a steep offroad trail with the trailer to fetch my fire wood.
Low gear and locker on but still got a fight.
Forgot to release the trailer brakes going down and a bit up to get to the road, so pulled the trailer full of fire wood out of there on stiff wheels.
5-600kg of birch.
So much added pulling power from the low gears.

Having tried for a few months now this very same kit 17/87 from Trail Gear, with 235/75 R15 tires, I can say the only loud noise is going up hill and when moving the car from a standstill, e.g. semaphore, it will always rattle a lot, only first and second gear, but never had this rattle downhill. It is to me it's similar to the noise I had when I had a worn out gearbox support. It sounds more or less like when you have to scrape the pots off the coal after cooking with wood.

My noise is only at torque like taking off hard or uphill or while pulling a trailer. Only at load and as you say only in first and a bit less in second.
Inspected all the bearings and all is good inside. New chain last year.
I have settled with it. It Will live as long as it Does.