Outer Limits 4x4 Board

Helping a mate install a series 3 rockhopper case on the weekend.

Are there any tips or tricks we need to know about ?

The S3 gears are already in a case. So it is just a case swap.

The old case is a 1.0 ltr. Will the flanges all match up ?

Anything else to consider ?

Cheers

Dan

In short yes sometimes their is flange diffrences but depending on what year Tcase it is. Try this thread for some more info:

http://www.outerlimits4x4.com/PHP_Modul ... hp?t=14334

Shorty40 wrote:Helping a mate install a series 3 rockhopper case on the weekend.

Are there any tips or tricks we need to know about ?

The S3 gears are already in a case. So it is just a case swap.

The old case is a 1.0 ltr. Will the flanges all match up ?

Anything else to consider ?

Cheers

Dan

what is it going into ?? and does it have the handbarke on the back of the T/case.
There are 3 flange sizes, 1.0, 1.3 small and 1.3 large, The large is normally post mid 1988. Keep an air impact gun handy and a small puller in case the flanges need to be swapped.

If it has a T/case mounted handbrake you may need a driveshaft from a pre mid 88 Zuk (1.3 small). The splines on the small and large bolt pattern shafts are the same, so you can run a small bolt pattern flange\shaft at the T/case end and a large flange\shaft at the diff end.

The larger ones could handle marginally more angularity as it has more room for yoke clearancing.

tip of the day:

put it in four low, unbolt the front and rear output shafts, remove the short arm completely and it drops out complete with jackshaft. (don't forget to disconnect the speedo and 4wd indicator loom connector

to save when you come to re-install the new box turn the rubber boot on the tunnel inside-out so it hangs down and then it is easier to line the stick (which is in 4l) up through the boot. attach the jackshaft to the t-case before you lift it up, you line up the lever and rear g'box spline at the same time

i've done the swap a couple of times now by myself, a trolley jack is ideal if you don't want to benchpress it into place

Hi Mate

Did mine recently all I did was print out pages to this site

http://www.zukiworld.com/month_070102/f ... nstall.htm

and you can do no wrong.

You will need a rattle gun 4 sure

HRZOOK

if it wasn't mentioned (too lazy to read), put the gear selector in before putting the case back on... is a pain trying to slot it in when the case is mounted. just undo the screws on the surround of the rubber boot

i've done the swap a couple of times now by myself, a trolley jack is ideal if you don't want to benchpress it into place [/quote]

if you choose a trolley jack over bench pressing the little jigger in you'd best be buying yourself a Hyundi or some other car that should be driven by a lady (girl)

Reinforce the mounting arms , and use urethane bushes & bolts inplace of the rubber mounts, see photos on xtreem's members page

stressed wrote:

suzukisam wrote:i've done the swap a couple of times now by myself, a trolley jack is ideal if you don't want to benchpress it into place

if you choose a trolley jack over bench pressing the little jigger in you'd best be buying yourself a Hyundi or some other car that should be driven by a lady (girl)

at least if you are going to quote me, quote me properly

i bench pressed it the first time or two, then got wise

and then bought a girls car to drive around in

Its not hard to bench press 5kg !!!!!

Thanks for the tips guys

The case went in without a hitch this morning. Took about 3 hours with breaks and piss farting around. Not bad for 2 guys without a clue

S3 gearing is wicked Makes his zook nice to drive on road in high range (22% reduction helps the 32s along nicely) and awesome offroad in low.