Outer Limits 4x4 Board

OK plenty has been talked about this but no one has told me how it works or anyting...
soo... here we go
basicly every gear in these to box's are a difrent ratio...
so... the imput shaft gear on a 1ltr is about HALF the size of the one in the 1.3. this making the cluster gear spin a whole lot slower, about half the speed actualy.. so the 1ltr low range gear is alot bigger to compinsate (so with standard tires you dont need 4th low to go anywhere) this is where we need the 1300 cluster... becasue of suzuki wanting the 1300 to be a more road bias zook. the gearing is about 17%higher all up in both ranges.. the imput shaft is alot bigger than the 1ltr and the cluster gear spins at a greater rate. so here lies our sulution. simply use a 1.3 low range gear set on a 1ltr high range and we get a whole lot better gearing! ruffly 17%reduction in high range and about 90% in low range!
ok enough of how it works...
Ok u will need basicly 2 x-cases... one 1.3ltr suzuki and one 1ltr 84- (i dont know about the pre 84's sorry)
and you will need both cluster gears, imput shaft and high range output gear from the 1ltr and the output gear from the 1300! and ouput shafts etc etc.
how do we do this!
there is a few ways that i have read about doing this... cut both the shafts in half and weld back together not exactly profesinal but i gues it must work!
the way im doing it!
take the 1300 cluster and mashean the high range gear completly off so you just have a flat shaft.
take the 1ltr shaft and mashen the center out of the hi range gear till you have a very snug press on fit..
run a nice beed of weld around it... do it in 1/4s and there you go. bolt box back together with 1300 low range gear's and 1ltr high range and drive away!
ok i will post up pics when i get the clusters back. but here is some pics of them in standard from!
On the left is 1ltr and right is 1300.
they are both sitting on the highrange ends.. notice the huge diffrence?
Phil
any questions feal free to pm me

Other people who have done this
http://www.geocities.com/Baja/Outback/3 ... bster.html

Good explaination...was plannning on putting a 1L complete transfer case in soon but maybe this would be a better option! Let us know how it goes and plenty of pics!! cheers

yep not a problem that is the plan.
after pulling it apart and stuff i have no ideah y any one would just go the 1ltr case.. this is about the same as a s1 rock hopper

HRZOOK wrote:http://ironbark.bendigo.latrobe.edu.au/~jeff/xfer2.htm

that sight is about as clear as mud... this is just a simple explenation.
Phil

OK guys
Some updates..
gears are still off being cut..
i have swaped the gears over on the last shaft. and orderd some new berings!
just some shots of the old and new gears!

(note: u MUST pull the spedo drive out before puling the last shaft out!!! thanks mark aka mud4b for this tip! i destoied a case tryin to.. yes im ruff)
Lucky i have a spair casing

these pics are the difrent between 1ltr and 1.3.. the litte one is 1ltr

Philby

difrence in output gears
again the bigger one is 1.3
Philby

and the diff on the shaft!
its starting to come togeher now.. get new berings on monday! and hopfuly gears next week!

When we first made them in 1990, the first series rockhopper was called the Rocklobster. It was made up of two Suzuki gears, part from the 1ltr the otherpart was 1.3ltr pressed them together and locked them together with a key lock. It was very simple and almost never broke or aleast I couldnt break mine in 3 years...........

Keep up the pics and info red_zook this is top budget suzuki tech!!

Brock.

hey iv been thinking bout this a bit and iff you havnt allready had the gears welded together it might be a good idea to have a key way cut and use some keysteal in the join. so your not relying on just the weld for strength.

that is why he is using interferance fit of the gears so the weld doesnt do all the work .alfas and bmw use this method for their cam gears ,yamaha use it for cams and gearboxs without welding

update.... (ol ate the pic by the way)
ok gears no longer going to be welded... since it seems that's how all the problems occur!
ok problems with welding...
it break.
the shaft is that hard the welds do SFA!
and one no one else has mentioned bar mark (suziworx)
welding actually bends the shaft and there 4 bearings were out heeps quick

SOULTION.......
the gears are going to be pressed together then...
4X holes drilled in along the join..
thread taped
and 4X extremely hi tensile grub screws Lock tited in with heaps of loctite. and hard in the end of the thread..

will this work?? that's the only question at the min! i don't thing they will break, and they shouldn't unscrew! but i have been wrong before today!

ideas ppl?
Philby

good luck tapping those holes in the case hardened gears, and yes that is the right way to do it, and make sure there is o runout on ur dial guage after assembley.

Red_Zook wrote:update.... (ol ate the pic by the way)
ok gears no longer going to be welded... since it seems that's how all the problems occur!
ok problems with welding...
it break.
the shaft is that hard the welds do SFA!
and one no one else has mentioned bar mark (suziworx)
welding actually bends the shaft and there 4 bearings were out heeps quick

SOULTION.......
the gears are going to be pressed together then...
4X holes drilled in along the join..
thread taped
and 4X extremely hi tensile grub screws Lock tited in with heaps of loctite. and hard in the end of the thread..

will this work?? that's the only question at the min! i don't thing they will break, and they shouldn't unscrew! but i have been wrong before today!

ideas ppl?
Philby

Keyways are the go ... as I am sure others have said your gonna have to anneal the metal to tap it for the grub screws and then reharden it ... not likley to make for a strong gear in my opinion.

I tryed to get some enginneers to put a key way in a suzi counter shalft a few months ago there machine just scated across without marking it. But good luck

Rhett wrote:I tryed to get some enginneers to put a key way in a suzi counter shalft a few months ago there machine just scated across without marking it. But good luck

Get better machines/cutters ... mine had 2 or 3 in it

yep they are hard..
sam recons harder to drill than tap for some reason..
owell he is the mashenest...
they are realy hard to cut etc tho!

does anyone know where i can just get the 1lt gear i have a 1.3lt tranny case already