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4.16 Transfer Case |
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(a.k.a. Rocklobster) |
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An inevitable part of any Samurai buildup seems to be lower transfer case gears. There are a couple of options available for this, a babylobster (stock 84 transfer case), rocklobster (combination of an 84 and a newer transfer case), or the GRSII (custom cut gearset - expensive). We chose to go for the rocklobster. This would give us an 88% lower low-range and a 12% lower high-range. |
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Stock '86 Transfer Case Gears: |
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Shown here are the internals of the '86 transfer case:
(A) Input Shaft
(B) Counter Gear
(C) Output shaft with High Output Gear |
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New SJ410 '84 Transfer Case Gears (with Suzuki part numbers): |
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Here is the internal diagram for the t-case scanned from a Suzuki manual. Click on the picture for more detail. |
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Here are the gears we bought from Suzuki with the Suzuki part numbers shown above each. They are for a 1984 SJ410 transfer case.
(D) Input Shaft
(E) Counter Gear
(F) High Output Gear
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Both Sets of Gears - '86 are A, B, C and '84 are D, E, F: |
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In the end you want to have the gears assembled in the '85 and up transfer case (Yes, you can use an '85 case but if you're running an '86 or newer samurai then you will need to swap the flanges/e-brake etc. over). We also re-used all of the bearings from the '86 transfer case. |
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Here's what you need to do:
1. Press the bearings off of the '86 input shaft (A) and then press them onto the '84 input shaft (D).
2. Press the High Output gear off of the '86 output shaft (C) and press on the '84 High Output Gear (F).
3. Now the most technical part (this requires a quality machine shop, we had Breeze Industries perform the work for us). You need to cut the larger gear off of both of the counter gears (B & E). Then the large gear from the '84 (E) has to be welded together with the smaller gear on the '86 (B).
4. Put the transfer case back together using the '84 input shaft (D), the new welded gear from step 3 (sorry no picture) and the '86 output shaft (C) with the '84 high output gear on it.
5. When putting it back together you can remove one of the bearings in the shift-fork mechanism so that you can get the 2-low option (see the write-up on off-road.com here).
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We had decided to do this conversion ourselves because of the hassles involved in getting things from the US. In hind-site next time we'd probably just order the complete gear-set from one of the US vendors because we probably didn't save any money by doing it this way. If you find an '84 transfer case then it would probably be worth it but ordering gears from Suzuki is quite expensive (not to mention we had to wait a month for them to come from Japan). Feel free to email us at r_and_d_suzuki@geocities.com if you have any questions or would like any help. |
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Click on the can of SPAM to go back to the main buildup page. |
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