Trevor R (QLD) replied:

Hi Craig,

Could it be you are trying to hear something as you have not exactly had the best start with that vehicle. I have just had the gearbox/transfer rebuilt on the Patrol and also have gear noise but I am putting that down to brand new gears and they may take time to bed in, if I still have noise in 1000km then it will most certainly be going back in my instance.
The beauty in your instance is the Mitsubishi warranty, you have plenty of time to get it sorted if it is not a brand new gear problem that needs to bed in. I would still jump up and down at Mits on Monday so your dealer is at least aware of your concerns and should be more inclined to help if it doesn't settle down in a thousand k's or so.

Hope it settles for you and you can enjoy the car for what you bought it for.
Regards, Trevor.

PS I had an auto Pajero in 96 that I wanted to sell after 2000km cause I hated the noises coming from the auto box on that thing and it lasted well till I sold it 170000km later. Maybe it is how it is supposed to be???

kev.h replied:

Hi Craig
In 2H you are not driving the transfer case in 4H you are so the noise in the FWD bits not sure if the new ones are gear or chain drive the chain drive ones get a chain noise in 4WD ( sounds like a bike chain) if that is all it is no problem may pay to ask what the drive system is ?? also when new in 4WD you have front diff gear/drive shaft noise thats not there in 2WD which changes the sound of the car
Regards Kev

Member - 'Lucy' replied:

Is it possible to give a more definedr description of the 'noise/s' rather than a general 'gearing noise'.

As Trevor said, once you leave 2H there are 'noise'/s' which are normal.

Member - Oldplodder (QLD) replied:

You could try the mitsubishi club forum.
May need to be a little more specific, or if you are not sure, ask about tying the noise down.

forum.pajeroclub.com.au/forum/

Other challenger users on this forum.

Mine is only super select I, not super select II, but I get some gear noise.
With all of the other noise (louder exhaust, and other rattles in the 10 year old car), not so audible any more in mine.

But you need to check it out.

It isn't like a mild gear crunching sound? Get this when the 4wd is not properly engaged. Do the dash lights keep flickering? If they do, 4wd has not engaged properly. You may ned to be firmer with the selector lever to actually engage the gear.

Is this your first mitsubishi 4wd? Maybe get a friend with a pajero or challenger to try it for you?

Zbub replied:

Hi Craig - simple solution - pop down to your not so local dealer & take another Challenger for an umm "test drive" ;) Drop it in 4H on a nice straight stretch of road. If you hear the same noise you can relax.

Challengers do make a noise in 4WD - the only time you won't hear it is if other noises cover it up such as aggressive tyres or the radio

You won't hurt her putting it in 4H on the tarmac as long as you don't go around any sharp corners or leave 4H engaged for a long time. I've accidently left my Challenger in 4H & driven 20km to town & back & its only when pulling into a parking space or if I turn the stereo down that I go Whoops !