See 2mm hole below.....can it be fixed?

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Yes very easily, with a nice TIG weld, access looks good and not covered in oil so is easy enough to do.
tabetha

 

result!

 

try some chemical metal in it first matey

 

Went to Halfords today but couldnt find any. Will try the bigger Halfords in Dundee tomorrow. Cheers!

 

or drill and tap a small hole and super glue a grub screw in there

 

How do you split the transfer box from the gearbox? I removed all bolts and tried to pull apart but the middle shaft must also need to come out first before splitting?? When I had this box on the 4x4 there was a grinding noise when moving away in 1st. I think the sprockets inside have thrown a tooth.