Outer Limits 4x4 Board

Well, mine took six hours from removing it from the car to drive away including a counter meal at the pub!
Don't rush. It is pretty straight forward. Leave out the middle detent ball and you can get 2lo if you want it.
http://www.suzukiclubuk.com/lowrockmod.html

want33s wrote:Well, mine took six hours from removing it from the car to drive away including a counter meal at the pub!
Don't rush. It is pretty straight forward. Leave out the middle detent ball and you can get 2lo if you want it.
http://www.suzukiclubuk.com/lowrockmod.html

Sounds good, thank you. i will try it just need to get a bearing kit
cross my fingers it all works

Took my case lot to the mechanic to get the bearings pulled off and new ones pushed on (case already in bits my puller wouldnt do it) and first we noticed the front output support bearing dosnt come in the rebuild kit. Then he rings me and tells me he has a list of other bearings I need to get as well. I bought the gears that come with gaskets seals and some bearings (not sure on which ones) I also got the "rebuild" kit so now I have double gaskets seals and some of the bearings but still need more bearings wtf? Not happy.
Anyway had my winge now others beware of this when you do it, I fell better now.
Cant wait to try them out.
Nik

Took my case lot to the mechanic to get the bearings pulled off and new ones pushed on (case already in bits my puller wouldnt do it) and first we noticed the front output support bearing dosnt come in the rebuild kit. Then he rings me and tells me he has a list of other bearings I need to get as well. I bought the gears that come with gaskets seals and some bearings (not sure on which ones) I also got the "rebuild" kit so now I have double gaskets seals and some of the bearings but still need more bearings wtf? Not happy.
Anyway had my winge now others beware of this when you do it, I fell better now.
Cant wait to try them out.
Nik

I got my rebuild kit from lowrangeoffroad and all I had to get extra was the tiny little needle roller bearing in the output? shaft.

Thats the extra kit I got and I knew I,d have to get the output support but the mechanic said he has a list?? Not sure whats on the list but I gave him the rebuild kit but apparently theres more, I,ll find out monday.
Nik

FFS so even with the rebuild kit I still need more parts!? Where to I get this needle roller bearing?

Ive got some more info, I had a look at the parts breakdown in the manual and it seems you also need output shaft support needle roller bearing part number HK1212 MU. About $13 from cbc and there looks to be 2 other needle rollers similar to the 2 that come in the kit dont have a part number on them yet.
Nik

Shit man I may just pay someone to do it if it needs all these parts.

put some pics up - i didnt need any of these bearings you guys are talking about i just replaced the input shaft bearings and another one as mine were in good condition - show and tell.... - dont pay someone i didnt and learnt heaps about it in the process how it all works etc so if i ever have to fix it ill know how!!!!

its not hard to do, id never done it before but found it fine!

So prey it's in good nick then?

anyone try the 8:1 & 6:1

Supercrawler Gears
any good

Ok the extras needed are output support bearing p/n HK1212, other 2 are genuine only rear output low needle 29984-80050, rear output high needle 29985-80050. My collet?? was damaged when the bearings were taken of and as the seal runs on this I,ll have to replace it as well genuine only but no p/n yet.
My first set I installed going on 10 yrs ago I didnt replace any seals or bearings and Ive regreted it so this time Im doing it properly as slop in the bearings may end up ruining your brand new gears.
I only needed help to pull the bearings off as my puller wouldnt do it but the rest isnt too hard if you have a manual.
Nik

Ok finally got my gears today. Much thanks goes to Locktup4x4 for their great service during postal dramas.

Now is this all I need or will I need more parts?

looks like u have it covered .cheers ron

X2

everything looks like it's there.

remember to grab a 1/4" BSP tap so you can press out the breather and tap the case for a proper barb while it's apart.

Steve.

My case already has extended breather hoses.

Glad I don't need any extras, you guys had me worried there for a minute.

I don't see the little needle roller bearing that goes in the output shaft.

want33s wrote:I don't see the little needle roller bearing that goes in the output shaft.

O bugger. What's it look like? There seems to be 4 needle roller bearings all up in the kit.

GRPABT1 wrote:

want33s wrote:I don't see the little needle roller bearing that goes in the output shaft.

O bugger. What's it look like? There seems to be 4 needle roller bearings all up in the kit.

From what i can see it looks like you got 2 sets of needle roller bearings for the counter shaft.
The one that is missing looks quite similar but the diameter of the bearing for the output shaft is about 10mm

paid_hitman wrote: The one that is missing looks quite similar but the diameter of the bearing for the output shaft is about 10mm

Yep.. thats the one I meant...
Here's a pic from my Maruti parts catalogue.
NUMBER 18 IS THE ONE.

So must I get that particular bearing or is it not essential I replace it? Where can I get one? And which number is it on that diagram?

[/quote]NUMBER 18 IS THE ONE.
[/quote]

GRPABT1 wrote:So must I get that particular bearing or is it not essential I replace it? Where can I get one? And which number is it on that diagram?

(no 18) lowrange off road sell it as an extra for about $7.50 but i think you can get it from cbc aswell

Righto, I'll have to order that one when I get the new mount then. Then it's crawling time

Yep number 18 is the one I spoke about a few posts up, 20 and 22 arnt in the kit but are suzuki only items part number quoted above 31 is the collet that got damaged when mine was pulled apart (see what happens when you pay someone to do it)
Nik

Mine seems to have 20 and 22 but not 18.

The "kit" comes with two 11s but not 20 and 22.
Nik

Maybe your kit does but mine has 4 needles roller bearings that size.

just some info on the calmini 5.14's in LOW RANGE...

Running vitara 1.6L 8v motor and 31's on a widetrack (WT diffs).

1st gear redline is 15km/hr
5th gear 3500rpm is 40km/hr

all the pickup is in the first 2000rpm, after that its all revvs.

COOOOOL!