heres a pic of the bent rod, which i bent back to straight, also bent the quarter circular throttle cable guide, and the spindle itself. And on the other end of the spindle, a return spring came of its mount, reset this. Oh and bent the end stop for the spindle, just out of shot, again straightened ...

Sorted it.

I had a bent choke lever arm, straightened it out, now running fine

End.

Tim

Update,

The front left wheel was massively out of balance 116 grams on one side 65 grams on the other. I have had it rebalanced, and checked all the bearings, etc, all is now fine.

Thanks for your help with this, all contributors

Tim

Gentlemen, Firstly Thank you for all your assistance so far, i am genuinely touched at by helpful you all are, and am now well on the way to an MOT. Secondly, and update. After sleeping on yesterdays nightmare, i woke up and had a brainwave. I knew i had a long quite thick, about 3mm, piece of angle...

OK, how do i get the flanges off, I'm guessing a special tool? were can i get one? or is it a make one job?

OK, update time. I have taken the old transfer box off, and refitted the ebay tbox. And have now discovered that it does not fit. The centres of the driveshaft to flanges on my existing set up, i.e the driveshafts and the flanges of tbox1, are 56mm With tbox 2 fitted i have tried to reconnect the dr...

Hi Scottie,
I have just bought one off a chap on ebay, and am off to pick it up now.
Would like to rebuild the other one, as i am intrigued as to what is wrong with it, and this way i have a spare.
Im in Reading Berks.
Tim

Good evening Dan, Firstly, thanks for the picture of the gearstick, mines gone, but using this helped me greatly to find neutral on the tbox. OK i think we are getting somewhere now, i have carried out the test as you described, and found the following In first there a kind of low but tired bearing ...

forgive my ignorance, this is my first 4wd vehicle - when you say put the tbox in neutral, do you mean, a place other than engaged in 4h or 4 l or 2wd, so basically put the stick somewhere between these, or is there a specific neutral position?

ok the noise is mostly present in 4th and a lot worse in 5th, i would not dare take it over about 35mph at present as it sounds like its going to go bang. i have checked the gearbox oil level, this is fine i have not tried your last point, putting tbox in neutral, and running thru the gears, what wo...