Suzuki Club UK

On Saturday I was driving my SJ when i noticed a metallic noise from the behind the cab. It was only audible when i started to put load on either as i pulled away or sped up having changed gear.
Eventually as i turned a corner and went to change gear i lost all the drive. It seeemed like i'd snapped the clutch cable. It hadn't snapped but when I adjusted it about 10 - 15mm the clutch seemed to engage again but the transfer box seemed to jump in and out of engaging.
I managed to push it in to 2H (i think) but now it does nothing. Even in gear the vehicle will still roll back and forth with out depressing the clutch pedal.

I bought my SJ in April and it was a project for a Guy Martin wannabe. On the surface it looked great but I've had hose and belt alignment issues.
Its got a Ford 1.8TDi engine and gearbox mated to what I beleive to be a standard transfer box. She's rolling on 31x10.5 R15 Bronco mud tyres.
I suspect that the transfer box has got either transmission wind (hence its stuck) or its given up completely and in fact I need to upgrade the transfer box gearing to cope with the change in engine/gearbox and larger tyre size.

Any thoughts are most welcome especially somewhere I could send the box to be upgraded.

Many thanks in advance.

Do you know if the transfer box was previously modified? If its had a home-made gear set put in the welding might not have been up to scratch and the gears could have come apart.
Richard Wattam (aka RockWatt) is the guy to talk to regarding transfer boxes!

I believe that the transfer box was unmolested. I have details of all the other changes that were made but nothing to suggest the transfer box has been changed from standard.

Thanks for your reply.

Did you have it in 4wd on the road?

I was driving in 2H with the hubs unlocked. But must confess to trying various things to engage some kind of drive before the transfer box got stuck.
As i said, I initially thought it was a clutch issue, then maybe a gearbox issue (because of no drive) and then the T box got stuck.

Having done some more searching online since buying her I now know that 4WD on tarmac is bad news. When I picked her up, the previous owner had left it in 4H and the hubs locked. My own fault for not checking but he did know that I was driving it from Norhamptonshire to Essex (approx 120 miles). I suppose I drove 15 miles before I realised!! The dash warning light is like me.... not always the brightest:)
As I had hose and belt issues and took a while to get round to repairing her I don't think I've done more than 50 miles since I got her home.

Oh dear, easy enough thing to overlook, in the excitement of getting a new stead home

Maybe the tbox is stuck in neutral. Get jack the back up and get underneath, spin the rear prop and the front prop will spin and the input prop wil spin freely if so.

I had a similar issue about a week ago. The t box was stuck in neutral so I pulled the shifter out and had a look. I thought my shifter sheet was worn so I replaced it, and although the new one was in identical condition it fixed the problem.

I had trouble with my cheap rock lobster box I had kept getting stuck in neutral had to take gear stick out and use a flat screwdriver and gently poke around Where the gearstick went in and try and get it working again

palo123 wrote:I had a similar issue about a week ago. The t box was stuck in neutral so I pulled the shifter out and had a look. I thought my shifter sheet was worn so I replaced it, and although the new one was in identical condition it fixed the problem.

Hey palo, just curious, your SJ is 'B' reg? was the original shifter sheet, black rubber or green nylon? ta!