Outer Limits 4x4 Board

Project building excites me and allow me to learn alot. Just recently I had made
significant progress in my SAS in a pajero with 40 series axles and ARB lockers.
I also just completed my diesel engine conversion for my Feroza. Its working great
and all my expectations with regards to its performance was met. The only problem
was it took a lot of time registering the change engine with government authorities.

I just bought my second Feroza and I want to do something different...

My biggest problem with the Feroza is the gearing. I am happy with the 1.6L engine
but torque is sorely lacking in the 1000 to 2,500 rpm range. When we go trailing
I have to rev my engine to 4000 rpm to get the torque and power that I need.
The only problem is that at 4000 RPM even at 1st gear and 4L, Im running
at 15-17kph, a little bit scary when you have muddy uphill trails and ravines at both sides
of the road. I envy my samurai friends with ultra low transfer case gears. They can rev
at 4000 rpm and still travel at a safe 5-7kph.

I solved the problem with my 2.0L turbo diesel engine from a kia sportage. Now I
have another Feroza and being somebody that gets ecstatic building things, I want
to install a samurai transfer case with UL low TC gears in my Feroza. I have ruled
out a double TC because it would make the propeller shaft too short and the angle
too high.

So here is my question. What if I remove a Feroza TC and replace it with a samurai TC?
What will be the problems? Will a machine shop be able to do this? Anybody have done
this before? Your inputs will be highly appreciated. Thank you.

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the little zook case it a remote unit so you might have to remoce the transfer and make a blabking plate with a short shaft

have you thought about other options?
ie hi lux
rover lt 230

another thing you have to watch it the hi range cause the zuk case isn't 1 to 1 high after you fit trail gears

@hillbilly, Hilux would also be okay. so with other transfer cases. The only reason why I choose the zuk
is because it has the widest and cheapest availability here in the Philippines.

Anyway upon doing more research, I discovered that there are zuk TC's used by the 660cc jimny's that
has a high ratio of 1.5:1 and a low ratio of 3:1 . The feroza has a high ratio of 1:1 and a low ratio of 1.754.
With this transfer case, I don't think I have to spend US$600 for an ultra low TC gears of the samurai.
Using this TC, I will gain 50% more torque on 2H which will compensate the loses on torque when you
increase your tire size from 27" to 32". At 4L the torque gain is equal to 3/1.754 = 71%. BTW the Jimny
TC is physically and has exactly the same external dimensions as the samurai.

Here is a picture of a Feroza Transmssion and TC. The illustration at the bottom is the transmission.


Here is an illustration of the Feroza transmission without the transfer case. If you look at it
carefully, You will see a potruding rod with a spline. A machine shop could put a flange here and
connect it via a very short propeller shaft to the zuk TC.


Here is a picture of a suzuki samurai/jmny TC.

Somebody on here has already done it. I'll do a bit of searching tomorrow if nobody else has found it by then.

Guy in Russia has done it..... no small task but its obviously possible. ( search.... ) He runs big ( for a feroza ) rubber and it was very high - not good for an off road feroza IMO.

The Sierra case ( of which there are a few variants ) is quite compact and gives reduction in high and low range if thats what you need. Its not the worlds strongest case but if your running a stock Feroza gearbox then strength isn't on your side anyway...

Just keep it real - and design from your end use backwards - not the otherway around. Don't change the case and then discover the gearbox is an issue then the IFS needs SASing then the diffs fail then the motor isn't powerfull enough, then....... get the picture ?

If the ratio problem is because of wheels the stock diffs are going to fail ( and no lockers... ) then.... then....

A feroza can be fixed...... but effectively its a Feroza body on other brands mechanical bits - how do i know......

Thanks MM, Ajferoza for the tip. Now I know it can be done.
Not planning to do any fancy. Just 32" tires and retaining the original
IFS suspension.

IIRC he removed the stock case, made a seal plate, and then a shaft from the Feroza box to the zook case,

New cross member and driveshafts Zook slipjoints are in the shafts.. which is all good.

Also range of transfer ratios available but there are variations of zook cases and IIRC not every ratio fits every case - check first.

Take a look here from our friend from Russia

Thank you HeroiCentaur for the info. Its very reassuring to see with pictures
how it was done. Im considering buying another Feroza and modifying it.