ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Suzuki 4x4 Forum => Topic started by: SP1086 on December 15, 2007, 12:59:23 PM
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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..
(http://zook4x4.oz20.com/Pics/Counter.jpg)
(http://zook4x4.oz20.com/Pics/Mistery-Bearing.jpg)
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What year case do you have? The Tcases changed in 91. The gears will only fit 91 and up
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calmini, thats your problem right there. :-X
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are you going to use that gear, the one with the big chip in a tooth??
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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?
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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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Also, is it possible that you have a gearset for a samurai and not a tracker/sidekick?
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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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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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How tall is the old gear vs the new gear? I suspect the case is pre 91.
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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. ;D ;D
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..
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Ok I've solved the Mystery bearing case... ;D
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???