Outer Limits 4x4 Board

Okay... after a lot of thought, my problem is that I am happy with just running a 2+2 lift and 235 mudders, but my low range gearing leaves a lot to be desired.

My current options are:
Dropping in some Trial Jimny gears or doing another Sierra box + Rockhopper swap out.

Problem is that to get the most out of both of these (retain onroadability), I will need to run 31s, 32s or 33s... meaning that to get the best possible 'upswing and tuck' from my suspension, I should really go up to an 80-100mm suspension lift - meaning panhards and castor correction.

The Trial Jimny gears will fix the high range, but not really drop me enough in low to be happy (from what I understand, the 27% is both high and low, as opposed to 27% high and 183% low with the Rockhoppers - but correct me if I am wrong, please)

I love the Sierra case swap - the DGTuning kit makes it a 2 hour-bolt in job - but I would need at least 33s to stop Stumpy being a dog on the road.... <insert 'here we go again' here>

Idea!

Has anyone ever dropped a transfer case from an efi Vit into a Jimny? Does it fit? What needs to be done? Would the gearbox need to be swapped out as well?
I am planning a 1.6 transplant later on anyway

This would be a perfect solution as dropping a set of gears into it would leave hi-range as is (meaning I keep my current lift and tyres - and onroad handling levels) and give me an awesome super-low low range.

Am I nuts... or is this feasable with some pushing and shoving?

Gearing options out there assume you are running huge tyres... there's nothing for 'mid-range'...

i assume your thinking dual cases? if so can be done and i'll pm you some details.

Dual cases? Hadn't really crossed my mind

I figured it would be similar to a Sierra case swap... but having to then deal with adapters plates and such...

PM me if you will

Someone really needs to develop gearing to suit mid-range tyres... they would sell a motza... imagine being able to gear down your zook on 215s...

whats wrong with the old 4.16 series one sierra gearing? works pretty well with 235 in a sierra

Is that the old Rockhopper 1 or the Series 3... or another brand?

My main concern is not sitting at 5000rpm @80-90km/h (Rockhopper 3 on 30s....) again

Stimpy (my last Jimny) ran 32s with a Rockhopper 3 - 4800rpm @ 105-110km/h. No good for 235s

On that note - question time

Okaay... not fully understanding the guts of a Jimny transfer case... is a reduction automatically carried over from low to high? Eg: Trail Jimny gears 27% overall.
Is a ratio reduction split - like the 27% - 183% Rockhopper 3 - possible with the Jimny gears?
From memory they are chain.... anyone?

...and before anyone jumps in here about 'why not just get a Sierra'... I don't want a Sierra... please keep in mind guys that many years ago questions and R&D got Sierras where they are today... and this is the purpose of my questions...

... I would really like to see a solution for Jimny's be developed - whether this is a Vit box with gearing for low only... or whatever... it's valuable R&D guys... Suzuki Jimny's are the last new, compact, solid-axled 4WD on the market... get with the program

APIO low range gears

I had a look at those but couldn't work it out... I sent a message to Yoshi, haven't received a reply as yet. Do you know which ratios they offer, and are they Samurai or Jimny direct-fits?

They do them for Jimnys. Robsjimny has them fitted now. They were originally fitted to Mugginsmoo's Jimny although he also used the TrialJimny high range gear as well.

cj wrote:APIO low range gears

X2 I've counted the turns 3.5 to 1 in low. I love it.


rob

Ahah... details please my man! What rubber are you currently running and what are your RPMs @ 100km/h?

Same as any other jimny with the same size tyre - the APIO low range kit only lowers low range.

Steve.

Ahah... what's the reduction percentage?

These may all seem like silly questions, but we need all this for the Jimny bible too

piss rockhopper off, just get a let of lowrange gears in 4.16 or 4.9(<--i have some for sale), put in a sierra case and will be all sweet on 235(with 4.16) or 30's(with 4.9's). Im talking 3000-3200 rpm at 100(not sure on jimnys other gearing numbers)

I know people beat lowranges drum alot, but they are just simple, cheap and easy.

Squik wrote:Ahah... what's the reduction percentage?

58%. They are 3.382 low range gears

cj wrote:

Squik wrote:Ahah... what's the reduction percentage?

58%. They are 3.382 low range gears

Ahah... thanks
I was just over chatting over at Jimny Se about Mugginsmoo Jimny... Zukiny said something about it running the Trial Jimny gears AND the APIO reduction gears...
If that is possible, it's a shame the Trial Jimnys weren't just 17%... would be perfect...
17% in high and 75% low in a Jimny box

Spike Sierra - yep, I've been that path before with my other JImny (32s, Rockhopper 3 in a Sierra box - brilliant). That's where this appears to be heading... the bugbear was getting low enough gearing for the tyres.
Unless I go with another DGT kit (costly but bombproof, easy and foolproff first go) it's so much stuffing around with speedo issues, brackets, shafts, flanges etc... been there done that
On that note - are the7 4.16 or 4.9 you have for sale?

Another option I was offered was just having two transfer cases... drive on the standard one then just bolt in a Trial Jimny geared one when I get there...

Squik wrote:

I was just over chatting over at Jimny Se about Mugginsmoo Jimny... Zukiny said something about it running the Trial Jimny gears AND the APIO reduction gears...
If that is possible,...

That's what I was saying. He only used the TrialJimny gears for high range and used the APIO gears for low range. Not cheap but it means you can stay with the standard t-case setup. Worked nicely with his 32's, locked and 1" of lift.

Ahhh... gotcha

Thing is I'm looking for a 235 solution... but thanks

I've done some working out and come up with the following (when the Jimny Bible gets started I will copy this into there as a sticky).
Everyone - feel free to advise corrections (I will edit this as we go) - this is just options I have found and after doing sums - looks like it's a Sierra case plus 4.16 swap.. but I am happy for further opinions on how the 4.16 will go with the 235s...

Whilst the APIO gears would be easy and suit me... I'm not paying that price for only 58% in low and nothing high

My findings:

For a Jimny running 215s or 235s:

APIO 58STAR reduction gears
Hi-range: No reduction
Low range: 58% reduction
Where: APIO Japan
Cost: $2040 (conversion of 169.000YEN) plus freight
Self fit?: Yes, if you are mechanically minded and have the tools
Good/Bad: No bad reports as such
Warranty? – None


D&G TUNING Sierra transfer case swap – using 4.16 reduction gears
Hi-range: 20%
Low range: 94%
Where: D&G Tuning – www.dgtuning.com
Price: Complete kit (you shorten your own jackshaft) - $874 plus
freight
Transfer case: Around $200 (?)
4.16 gears - $ (?)
Case rebuild kit: $ (?)
Total: $1900 (approximately)
Self fit?: Yes, if you are mechanically minded and have the tools
Good/Bad: The kit is foolproof
Warranty?: Unknown

TWIN CASES (Joeblow’s suggestion)
Hi-range:
Low range:
Where/who/how:
Price: Need 2nd Jimny or Vitara case ($300-$350??) Plus???
Self fit?: Probably not
Good/Bad:
Warranty?: I’d say no...


For a Jimny running 30s to 33s:

TRIAL JIMNY GEARS
Hi-range: 24% - 1,63:1
Low range: 24% - 2,65:1
Where: Trial Jimny – www.geocities.com/trialjimny/jimny.html
Cost: $1700 plus freight
Self fit?: Yes, if you are mechanically minded and have the tools
Good/Bad: Good reports
Warranty?: Yes – 12 months (including competition)
**ADD APIO GEARS - Plus $2040


D&G TUNING Sierra transfer case swap – using 6.?? reduction gears
Hi-range: ??
Low range: ??
Where: D&G Tuning – www.dgtuning.com
Price: Complete kit (you shorten your own jackshaft) - $874 plus
freight
Transfer case: Around $200 (?)
4.16 gears - $ (?)
Case rebuild kit: $ (?)
Shorten jackshaft - $120
Total: $2000 (approximately)
Self fit?: Yes, if you are mechanically minded and have the tools
Good/Bad: The kit is foolproof
Warranty?: Unknown


*Gearing price comparo – fixing gearing on my Jimny (based on 4in with 235s)

APIO Star58 - $2100 – no larger tyres needed, no engineering
Trial Jimny - $1700 + 30in tyres $1500 + 80mm lift $900 – $4100
DGTuning - $874 for kit + $690 4.16 gears + $250 case + $120 jackshaft - $2034
Twin Cases - $300 case + $800 labour - $1100 (speculative only)
Spare case (swap onsite) with gearing - $690 4.16 gears + $300 case - $990

There's a great deal more than $1100in duals if you're paying for labour.

I'd say the D&G with 4.16 gears looks like the best compromise to me...

Steve.