Suzuki 4WD Club of Victoria

so my front input shaft on my transfer case has about a third of the teeth stripped off it
any idea as to what would cause this? everything else in the box seems fine

I assume you mean the input shaft, not the front output.

This is the smallest gear in the transfer therefore it's always the one that fails.

No idea on cause, without doing expensive failure analysis you might never know if it was a material or heat treatment problem. Whose gears?

Steve.

Trail Tough gears 6.4s
Do you think it is more likely to be a fault in the gear or another factor like abuse or installation errors?
I'm pretty sure all the bearings were done when I put them in the case to begin with.