soo... here we go
basicly every gear in these to box's are a difrent ratio...
so... the imput shaft gear on a 1ltr is about HALF the size of the one in the 1.3. this making the cluster gear spin a whole lot slower, about half the speed actualy.. so the 1ltr low range gear is alot bigger to compinsate (so with standard tires you dont need 4th low to go anywhere) this is where we need the 1300 cluster... becasue of suzuki wanting the 1300 to be a more road bias zook. the gearing is about 17%higher all up in both ranges.. the imput shaft is alot bigger than the 1ltr and the cluster gear spins at a greater rate. so here lies our sulution. simply use a 1.3 low range gear set on a 1ltr high range and we get a whole lot better gearing! ruffly 17%reduction in high range and about 90% in low range!
ok enough of how it works...
Ok u will need basicly 2 x-cases... one 1.3ltr suzuki and one 1ltr 84- (i dont know about the pre 84's sorry)
and you will need both cluster gears, imput shaft and high range output gear from the 1ltr and the output gear from the 1300! and ouput shafts etc etc.
how do we do this!
there is a few ways that i have read about doing this... cut both the shafts in half and weld back together
not exactly profesinal but i gues it must work!the way im doing it!
take the 1300 cluster and mashean the high range gear completly off so you just have a flat shaft.
take the 1ltr shaft and mashen the center out of the hi range gear till you have a very snug press on fit..
run a nice beed of weld around it... do it in 1/4s and there you go. bolt box back together with 1300 low range gear's and 1ltr high range and drive away!
ok i will post up pics when i get the clusters back. but here is some pics of them in standard from!
On the left is 1ltr and right is 1300.
they are both sitting on the highrange ends.. notice the huge diffrence?
Phil
any questions feal free to pm me
Other people who have done this
http://www.geocities.com/Baja/Outback/3 ... bster.html
