SJ413 4.9 transfer case gears

[wayfastwhitee]

Decided to break the bank on some new gears

http://www.lowrangeoffroad.com/index.php/suzuki/samurai/transfer-case/4-9-1-tcase-gears.html

Once they arrive from Utah i'll try to start a small thread; if anyones keen to see whats going on in there

[farmerboy4]

easily one of the best mods you can do in a suzuki

good choice

[wayfastwhitee]

easily one of the best mods you can do in a suzuki

good choice

ha yeah thanks, was tossing up big time with just getting a 410 box but you've got to love the huge reduction for crawling!

[wayfastwhitee]

Gears arrived in Auckland on the 5th of feb.
No one has contacted me until i chased it up today and owe customs $136 in gst and fees

[Swamped]

That sets easy as to install, came with everything needed.

[UBZ]

have a read up on shimming the transfer case gear sets properly .
otherwise it is Likely you will have alot of gear chatter .
I would replace as many bearings as you can whille your in there.
the hard to find needle rollers can be brought from suzistore.
the main things to remember ,
remove the speedo drive gear before disassembly
rebuild the gearsets around the center plate , then put the outer covers on last.

[wayfastwhitee]

have a read up on shimming the transfer case gear sets properly .
otherwise it is Likely you will have alot of gear chatter .
I would replace as many bearings as you can whille your in there.
the hard to find needle rollers can be brought from suzistore.
the main things to remember ,
remove the speedo drive gear before disassembly
rebuild the gearsets around the center plate , then put the outer covers on last.

The kit comes with needle bearings. I've managed to find the five roller bearings at trade price Suzuki wanted 60-70 each for oem.
Ok cool, i'll look into the shims.
One question i do have is that about three weeks ago i replaced the rear output seal as it was stuffed, started leaking a substantial amount of oil. Anyways, I noticed there was a small amount of freeplay in the rear ouput shaft; is this a usual occurance? I figured everything should be pretty tight

[UBZ]

that kit only has the needle bearings for the counter shalft.
there are more needle bearings on the main output shaft and for the front 4wd output.

play in the rear output shalft would most Likly be related to the main roller bearings which you are replacing . also have a close look at the high/low and 4wd slip yokes . A couple of cases I've had apart were very badly worn on the splines . Casuing alot of slop in the gear engagement and caused the transfer to hop out of gear at times.

[wayfastwhitee]

Oh okay, thats cool. The plan is to pretty much do a complete overhaul so i'll pick those up too.
Hopefully you're right; all the roller bearings were replaced about two years ago though, but it'd be nice if it was just that.
Had a look on lowrange and found out about the shims, pretty simple, just have to pick some up on monday

[wayfastwhitee]

gears arrived yesterday and almost finished getting the case out, will strip it tonight

[wayfastwhitee]

Just need to buy bearings, shims and oil tomorrow, put it all back together and its done

[wayfastwhitee]

[wayfastwhitee]

play in the rear output shalft would most Likly be related to the main roller bearings which you are replacing

ended up being the rear output bearing, it was completely stuffed and only about 2-3 years old

[wayfastwhitee]

Got the gears in last week and took it for a play down Diversion Road; went well although i'd like to get some side bars made up as it gets a bit hairy in tight places