Outer Limits 4x4 Board

I had a problem where my Sierra wouldnt go into low range, it felt the same as when in N on transfer case, and the replies (in my previous thread) i got suggested to replace the sheet bush, which i did. Problem is still there.

I have the transfer out of the sierra now, on a bench.
Changing gears with a screw driver, and spinning shaft by hand, i can get 2H, 4H and Neutral to work. (I knew they worked anyway, because they worked while driving) 2H and 4H seem to spin 1:1 with the shaft. (ie all 3 couplings spin at same speed)

When selecting 4L, and spinning the shaft by hand, the front and rear couplings DO spin, at approx a 4:1/5:1 ratio (would this be correct for crawler gears??) but as soon as a load is put on front or rear shaft couplings, such as my other hand, they 'slip', so no power would have transfered to front or rear diffs.... this is my problem.

Thats as far as i got with it this afternoon. I dont have a workshop manual, so i will be buying one before opening up the case.

Has anyone had the same, or similar problem before?
Any other suggestions?

Thanks (Hope this doesn't seem like a double post, i felt it deserved its own thread!)

Mike

Don't buy a workshop manual. Download it from www.suzukiinfo.com

Sounds like something is wrong but not sure what without seeing it.
Jas.

Tough to know without seeing, but I'd say it'll have to come apart.

Sounds like it's not staying engaged in gear under load. That fact that it at least spins free means the gears might still be in the right number of pieces. Was there any metal in the oil?

when in low the front and rear aren't locked, is this the same as 4h

just cruizin' wrote:when in low the front and rear aren't locked, is this the same as 4h

No, 4H works as it should... locked

Mike

download the manual and look at the interlock, chances are its been apart before and not put back together properly before seen it 2 times ,norm after some idiot has rebuilt or put gears in who has had no idea

Got the manual downloaded.

Tried to open up this evening... got as far as trying to remove flanges, and by hand they wont budge! tried clamping flange in a vice and hitting a spanner with 4 pound hammer, still wont move. Even tried an electric rattle gun.

So tomorrow morning i will have to spot heat with the oxy torch, then should move. Failing that, then chisel/die grind nuts off and get new ones.

I cant be the only person whose had this problem, so how did other people overcome this?

Thanks
Mike

I drilled two holes in a piece of angle 3 feet long and bolted that to the flange and then put a piece of pipe on a 3/4 breaker bar with socket.
Once the nuts crack they come off easily enough. Then a pulley puller to remove from shaft.
Don't heat them as you may lose the temper in the shaft.
Oil helps too.

Jas.

Is it a coil spring or a sj70 or 50 ?
if its got a coily transfer they sieze the shifter all the time, 2nd worst transfer suzuki ever made

scooby_74 wrote:Is it a coil spring or a sj70 or 50 ?
if its got a coily transfer they sieze the shifter all the time, 2nd worst transfer suzuki ever made

And the first would be?

sj 80 96 on

type 5 SN413 jimney 2006 on
crap transfer like the coily but they put an electrical switch on the front that small sticks break and no 4wd.
3rd worst 98 grand vitara v6 auto or 4 potter jumps out of low range until modified hub goes into transfer bout $600 part

Thanks for the info.
I managed to get the nuts off, and found my problem.

Counter-shaft had snapped in the centre of the 2 gears.
It snapped on a weld, which i assume is not meant to be there, and just a cheap fix?

Can anyone tell me what the standard low range ratio for the sj70 transfer is? (eg, how many turns of the input, for one turn on the output?)

Also, being new to sierras i wasn't sure of the model code for mine. I checked rego paper and vin is JSA0SJ70000###### so im assuming sj70. Im trying to find info an all sierra models (different variatios, etc), but cant seem to find much on google. just a heap of GMC's.
Anyone have a good source of info?

Thanks
Mike

Try the bible on here and www.suzukiinfo.com

Also AFAIK your model is one of the best, last of the leafies and has the most aftermarket support.

mike_nofx wrote: Counter-shaft had snapped in the centre of the 2 gears.
It snapped on a weld, which i assume is not meant to be there, and just a cheap fix?

it sounds like its had a rocklobster done (the dodgy way) which gives a low range ratio of 4.16:1. hirange is 1.590:1

you can get an equivelant ratio gearset from the states for $399.00US from www.lowrangeoffroad.com aslong as your not in too much of a hurry for it.

it could be a good excuse to buy some lower ratio gears too.

mike_nofx wrote:Thanks for the info.
I managed to get the nuts off, and found my problem.

Counter-shaft had snapped in the centre of the 2 gears.
It snapped on a weld, which i assume is not meant to be there, and just a cheap fix?

Can anyone tell me what the standard low range ratio for the sj70 transfer is? (eg, how many turns of the input, for one turn on the output?)

Also, being new to sierras i wasn't sure of the model code for mine. I checked rego paper and vin is JSA0SJ70000###### so im assuming sj70. Im trying to find info an all sierra models (different variatios, etc), but cant seem to find much on google. just a heap of GMC's.
Anyone have a good source of info?

Thanks
Mike

Sounds like you either had a rock lobster style gearing, which is a combination of 1L and 1.3L gears weded together, or you had one of the VERY early series 1 transfer gear sets, from memory these were welded. Either way, its time for new gears. For the money, you may as well get some lower gears while your there. The 6.5's are pretty well priced, and give you plenty of scope with tyre changes later on.

Layto....

6.5's FTW!

Just used mine for the first time offroad yesterday and I am in love.