MY CRAWLERS DONT FIT AHHHHHHHHHHHHHHHHHHHHHHHHHHHHH!

SP1086

MY CRAWLERS DONT FIT AHHHHHHHHHHHHHHHHHHHHHHHHHHHHH!

« on: December 15, 2007, 12:59:23 PM »

Firstly I Have a 92 Vitara SWB

After much buggering around I got my transfer case apart on the bench and started installing my Calmini Crawler gear set. Following their booklet & the gear guide on this site to the T I got to stp 41 and realized that the Counter Gear is too long or something.. The gear is like 10mm longer than the standard one! You cant place the thrust washer on the top of the counter shaft as the gear covers the locking ball hole..

I have checked over all the previous steps several times but I have done everything correct. Aside from that I have a Mistery bearing that came with the set and I cant see what its for?

I have email Calmini to see what they have to say. $:-\$

Anyone else have this problem before.. Any help or advise will be much appriciated..

« Last Edit: December 15, 2007, 01:01:54 PM by SP1086 »

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sidekicksrock

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Re: MY CRAWLERS DONT FIT AHHHHHHHHHHHHHHHHHHHHHHHHHHHHH!

« Reply #1 on: December 15, 2007, 01:38:32 PM »

What year case do you have? The Tcases changed in 91. The gears will only fit 91 and up

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phloop

Re: MY CRAWLERS DONT FIT AHHHHHHHHHHHHHHHHHHHHHHHHHHHHH!

« Reply #2 on: December 15, 2007, 02:33:55 PM »

calmini, thats your problem right there.

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locjaw

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Re: MY CRAWLERS DONT FIT AHHHHHHHHHHHHHHHHHHHHHHHHHHHHH!

« Reply #3 on: December 15, 2007, 03:09:12 PM »

are you going to use that gear, the one with the big chip in a tooth??

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SP1086

Re: MY CRAWLERS DONT FIT AHHHHHHHHHHHHHHHHHHHHHHHHHHHHH!

« Reply #4 on: December 15, 2007, 08:02:24 PM »

Thanks so much guys for the quick reply's..

Different cases hey, Ahhh ok well thats a bit of a relief.. My Zook is a 12 month 92 but maybe the box isnt.. Oh and that gear that looks chipped isnt. Thats just a bit of Blue Grease..

So if I had to goto a 4x4 Recyclers and get an 92 or on transfer case is there any way of telling them apart, or is it only internal differences?

« Last Edit: December 16, 2007, 12:48:27 AM by SP1086 »

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crikeymike

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Re: MY CRAWLERS DONT FIT AHHHHHHHHHHHHHHHHHHHHHHHHHHHHH!

« Reply #5 on: December 16, 2007, 10:49:45 AM »

Maybe that bearing is to fix the fitment problem that you're having?

All the bearings i used (which were the original bearings) don't have a race around them, just needles on both the inside and out. That piece would have to be mentioned somewhere in the instructions i would think.

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1993 4-door Sidekick
3" hybrid Calmini/OME lift, 2" B/L, Rear air locker
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crikeymike

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Re: MY CRAWLERS DONT FIT AHHHHHHHHHHHHHHHHHHHHHHHHHHHHH!

« Reply #6 on: December 16, 2007, 10:50:39 AM »

Also, is it possible that you have a gearset for a samurai and not a tracker/sidekick?

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1993 4-door Sidekick
3" hybrid Calmini/OME lift, 2" B/L, Rear air locker
Shrockworks bar & sliders, Full skid plates
4.24:1 t-case
WAZUKS member - visit http://www.wazuks.com

SnoFalls

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Re: MY CRAWLERS DONT FIT AHHHHHHHHHHHHHHHHHHHHHHHHHHHHH!

« Reply #7 on: December 16, 2007, 11:01:58 AM »

one other thing I was thinking was are you sure the lower thrust washer and ball are correctly seated?

I've not done the calrippi set, (but did do the TT set) ... I seem to recall at one point I saw something simlar to your pic and it was because the lower thrust washer wasn't seated correctly. (then agin it was pretty obvious, so I would assume you would also notice it).

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brentd27

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Re: MY CRAWLERS DONT FIT AHHHHHHHHHHHHHHHHHHHHHHHHHHHHH!

« Reply #8 on: December 16, 2007, 12:58:47 PM »

Are you sure that's blue grease? That tooth, second from where the arrow is closest too sure looks like it's got a big chunk out of the tooth.

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Mikerpm4x4

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Re: MY CRAWLERS DONT FIT AHHHHHHHHHHHHHHHHHHHHHHHHHHHHH!

« Reply #9 on: December 16, 2007, 06:10:20 PM »

How tall is the old gear vs the new gear? I suspect the case is pre 91.

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SP1086

Re: MY CRAWLERS DONT FIT AHHHHHHHHHHHHHHHHHHHHHHHHHHHHH!

« Reply #10 on: December 17, 2007, 04:07:40 AM »

Yeah its grease... came from me putting some on the top of the gear to see if it was hitting anything on the other half of the case when I put it togeather turns out it was.

Anyway good new is I got another transfer and they all fitted perfect.. Just have to wack the box & transfer back in and I can go for a test drive.

Still dont know what that bearing is for?

Again thanks a heap for the help..

Still waiting for Calmini to get back to me.. Maybe they are on hollidays allready. Hopefully they will know what that bearing is for..

« Last Edit: December 17, 2007, 04:09:36 AM by SP1086 »

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SP1086

Re: MY CRAWLERS DONT FIT AHHHHHHHHHHHHHHHHHHHHHHHHHHHHH!

« Reply #11 on: December 18, 2007, 08:09:41 AM »

Ok I've solved the Mystery bearing case...

Its the Front or Rear Drive shaft yoke bearing.. If Calmini give you them in the kit why they dont give you 2 of them, but anyway thats what its for.. Now all I have to do is work out how to get the old ones out???

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