Got one!

I didnt want to cut my body so removed the lever (which can be done from above by removing 3 bolts) I then cut the lever in the middle of the swan neck, rotated it about 2-3mm and welded it back togeather. Clears fine now and I know I still have a seal to prevent water coming in through gaiter/body and I havent invited rust to fresh cut metal

Well done mate - no point buying a nice looking one to take it off road as you'll just wince everytime you scratch it!

Come on then, where's the piccies???

Kirkynut

srcars wrote: I didnt want to cut my body so removed the lever (which can be done from above by removing 3 bolts) I then cut the lever in the middle of the swan neck, rotated it about 2-3mm and welded it back togeather. Clears fine now and I know I still have a seal to prevent water coming in through gaiter/body and I havent invited rust to fresh cut metal

sounds like a good way of doing it. How do you get at these 3 bolts?

Is it just a case of lifting the carpet (somehow) and I will be able to get at the 3 bolts?

theres 4 screws holding the gaiter on take them out & take knob off the top of lever & you will see the bolts holding the lever in the box under there

Been having a look tonight, and im now at this point:



If I undo these 3 bolts, will the lever just pull out of the transfer box?

I can select 4L with the gaitor removed and it stays selected but the lever is right up against the opening in the floor.

Here are a couple of pics aswell :

Looks like you've got a good motor to start with there mate.

In relation to the transfer box. You have to undo those three bolts and the outer ring they hold down comes off.

Then there is another ring underneath which can just be seen in your picture. It is sprung and needs pushing down and turning to allow slots in it to line up with two prongs like a bayonet bulb fitting sort of affair.

I know Martin and possibly Jason (Ooky_123) have managed this but I have a Rocklobster now and had my old Jimny transfer box on the garage floor and wanted to know how the lever came out but no matter how hard I pushed down on that lower ring and turned it, I could not get the thing out.

So it must be rather tricky with the box in the car, or maybe some are easier than others.

If you've ever played with an SJ transfer box lever, it's the same except it has these three bolts and the top ring to take off first.

You might find it easier to drop the transfer box and have a go. It's not too hard to do but the 3 rubber mounts might break up or the threads shear and they are £15.00 each from Suzuki!

I found pressing the lower ring down with a flat headed screwdriver either side in the gaps to turn it helped but still couldn't get it out - maybe I was being a big wimp though?

Kirkynut

I will give it a go tomorrow, its dark now.

If i cant get it loose i will hit it with a massive hammer, normally does the trick.

Another question... sorry!!!

With the gaitor removed i can obviously see the shafts connected to the transfer box. In 2wd both of the front facing shafts are turning, does this mean the hubs are permanently engaged?

Im thinking yes.

All sorted now... just need to put the interior trim back in place!

removed the lever, then "lordnev" cut a wedge out of it, bent it forward and welded it back up. Jobs a good'un!