Transfer case gear change?

[Phils]

I'd really like to have a lower gear ratio in the transfer case. I've seen some kits available online.

Can anyone offer suggestions or recommendations? Maybe a good place to buy from (or, equally as good, the name of anyplace I DON'T want to buy from)?

Looking online I've seen that installation has "some grinding required". Any big deal there?

Are there choices of transfer gear ratios?

Phil

[Billjohn]

Wow. Innocent questions with big answers.

The first thing you will want t do is figure out what you want to do with the vehicle.
Is the gearing change just to make up for bigger tires on the highway?
Or do you want to offroad with it?
Or do you want to rock crawl with it?

Different questions requiring different gear ratios. You can get an idea using a gear calculator that can be found all over the net. Lots of sites have their own. You can plug in the stock gear ratios and then experiment from there. Here is a link to our calc page at iZook.
Gear Calculator
And here is a link to the gearing tables that list most of the ratios that are out there.
Gearing Tables


Old school thought was that if you only needed to adjust to 31's, you could get a 4.16:1 (GRS1) to do the job. If you wanted to go to 33's you would want a 4.89:1 (GRS2). But you can get more power (with a slower top speed)
with a 5.1 - or 5.4 - or 5.8 - or 6.4 - or even 8:1 gearset.

If you are not comfortable with ripping apart your t-case, you can get complete units from Petroworks, Trail Tough or Low Range Offroad. They will also give you some pretty good advice on what you need for your situation.

PetroWorks
Welcome to the Trail Tough Products
Welcome to Low Range Off-Road, your off-road parts and accessories source for your Suzuki, Toyota, and Jeep

[Phils]

Thanks again Bill.

This Sammy is only used on our forest trails. My wife has asked for lower gearing so that she can go slower without lugging/killing the motor.

If it ever is sold to someone else I figure the lower gearing would be desirable, especially if a new owner was gonna put bigger tires on and lift it. (Not likely we'd ever sell it .... it'll probably just become part of the equipment on our parcel, like my tractor).

I plan on keeping the stock size tires for our use since there are some sidehills and this IS a Samurai and I have a street tread on it in order to 'tread lightly'.

I've attached a pic of how it's used: "toy"

But I didn't know anyplace better than here to start the process of figuring out how to fulfill her request. I'll be checking out Petroworks (more.... I've been there many times already) and the other links.

But I'm ready for suggestions if the above info is indicating one ratio over another.

Phil

[Phils]

and normally the little one has the seatbelt around him, even going 4mph, but she'd just gotten stuck in the mud and I took the photo before going to get the tractor but afer she'd undone his belt.

Phil

[Billjohn]

Looks like Gary doesn't offer the GRS1 any longer. If it is just to run around the 'parcel' you can't go wrong with his GRS2 setup. It has good stump pulling gears. Good luck.

[Phils]

Well it seems 4.89:1 or 4.9:1 will be the way to go. Now to figure out how to do it for less than $600! I did notice one "economy" kit for less but then I'd have to find the gaskets and any bearings that needed replacing.

Thanks again for the links.

Phil

[Billjohn]

Remember to replace the main shaft. The 20 year old original is going to be worn and you can destroy a new set of gears re-using the worn shaft (been there, done that...)

[Phils]

Originally Posted by Billjohn

Remember to replace the main shaft. The 20 year old original is going to be worn and you can destroy a new set of gears re-using the worn shaft (been there, done that...)

WOW Bill... thankyouverymuch for that nugget of wisdom. That "economy" kit I believe only had gears so I guess it's the $600 "option" only.

Phil

[hotrodsami]

Rocky road outfitters has some kits for less than $600(US) that come with Gears, gaskets, counter bearings, thrust washers, shims, and the counter shaft
and instructons
Suzuki Samurai Gears and transfer case kits

good luck

[Billjohn]

There ya go!