Outer Limits 4x4 Board

put a rebuilt transfer case with calmini 5.14s into the zook a couple of weeks back.... used it in anger for the first time on the beach over the new year, had had major dramas with it... very zook way to start the new year


2H works with no dramas, and the shift forks seem alright as they move freely using a screwdriver. 2L seems to work alright, but when i have it in 4H the gear lever jams into position (bottom, right hand side), with the case in 2H

it's not the shift sheet/bush thing, i've put a new one into it. two options i can think of:
- the forks cut out bit is damaged allowing the lever to slip and jam... but doesn't look bad when i eyeball it.
- other possibility is that there's a difference between that 1.3L transfer case and my old one, making my gear lever slightly too short and allowing it to jump position and jam??? are there any differences in transfer cases over the years?

help me!!! very frustrating....

stumped wrote:2H works with no dramas, and the shift forks seem alright as they move freely using a screwdriver. 2L seems to work alright, but when i have it in 4H the gear lever jams into position (bottom, right hand side), with the case in 2H

WTF?!

2Hi OK
2Lo OK so the tcase has been modified ?? or are you just not locking hubs in
4Hi Gear lever Jams or do you mean tcase lever
2Hi I thought you said this was no dramas

You may be Stumped but I'm confused

mate i can send the lever down to you...

damn i was tired when i wrote that


there is no 2L, i meant 4L just had a spaz.. gear lever = transfer gear lever. the rest makes sense tho... it works fine in 2H and 4L, but when shifted into 4H the lever jams in the 4H position after a while.... but the forks are back in the 2H position - hence no front drive.

it looks like the lever jumps out of the slots in the forks and jams in the wrong slot. it make sense when u look at the forks, the slots are diagonally opposite in 2H and 4H, the lever looks like it's jumping diagonally and then you can't move the forks cos one won't move til the other is in the correct position.

make sense yet? hard to explain...
anyone heard of minor changes in the transfer cases? thought it might be possible cos they changed other lil things like flange size etc..

mud4b wrote:mate i can send the lever down to you...

yeah, would appreciate that dude....

Check with suzuki the part numbers for the different levers as i think there are the same.

cheers

in my part finder.....

type 4-5-6-7 sierra 1.3....all run the same t-case shifter...

p/n...29341-80701


410 sierra runs a different stick...(it has a larger select on the end of it)
p/n...29341-80051

coily sierra is totally different,and wont fit into the t-case..

410 being the coily?

hmm... will have to compare when i get that one ur sending, could just be worn or something

damn i hope this fixed it

410 is the 1l like my 84

yup 410 is a 1lt..


dont stress we will fix it....

Make sure ya send the stick as well. -Mick-



cheers

nicbeer wrote:Make sure ya send the stick as well. -Mick-



cheers

the stick is sent...

cheers dude.... unless it turns up today i won't be able to try it for two weeks, am leaving for a bit of a holiday early friday

will let ya know...