Transfer chain not fitting low range gears from Trail Gear kit

Dear friends, 

I've already contacted Trail Gear customer service about it, but maybe someone already noticed this in the past, I'm having problems with the transfer kit 304088-3-KIT. I've got a Suzuki Jimny, mechanic/manual transmission, 2017, here in Colombia. 

These days the mechanic is mounting the kit: T-Case Gear Set, Chain Drive, Electric/Pushbutton, Jimny, 17% High/87% LowSKU: 304088-3-KITI've bought a new OEM transfer chain, because the old one was already elongated. However, the mechanic is complaining that the chain is not matching the sprockets of the gears in the kit, because they are smaller than the original ones. In the manual Trail-Gear mentions that the chain needs to be changed only in the case of automatic transmission (mine is manual) to a 29225-84A00, I don't know if I need to buy that chain then, is it different from the one I have?Did you fit this kit straight away or did you have to change the chain to a specific one?

Thanks for your help!

 

 

Just looked on jimnybits here in the UK 
No mention about the chain 
Only saying the actual case needs a small amount of grinding to give chain clearance 
This should be shown in the install guide 

In addition the new sprockets are higher than the originals, so it make the mechanic suspect that the chain has to be different? 

   



 

Width:
- Chain: 28.25 mm
- Original gears: 23.85 mm
- TG (kit) gears: 30.25 mm

Does anyone here know what's the width of the manual transmission chain?? But I bet my manual jimny has got a manual chain already, so I don't understand which chain do I need...

2922584A00 Genuine Suzuki CHAIN 29225-84A00

Part number for the original push button transfer case Edit: CHAIN for manual gear jimny 2005 and newer above.

I have the same 17/87 trail gear set in my jimny. I reused the original chain that was in my transfer case from new, and after 40000km's it was replaced with a new one, same kind, with part number as above.

All sprockets and gear wheels fit just fine in my case.
as mentioned above I had to grind off a splash rib inside the box as the trail gear manual explaines.

You have clearly the wrong kit for your transfer case. could be a difference in markets what case your car come with, or trail gear has sent the wrong parts.
To me it looks like my parts had the wider variant but I have not measured this as there never was any need to.

Edit 2: You should not try to fit wider sprockets/gears into your transfer case by the way, you will not be able to fit the lid back on.

Edit 3: or if the base of the Gear wheel is excactly as wide as the one you remove it might. But take measurements and check thoruoghly.
           - Looks to me like the wider chain is 1 1/4" wide by some listings on line so the one I gave the part number for here is most likely the one that will fit the wider gear wheels in the kit.
             I am not able to take measurements of my own wheels now, I am travelling until Sunday / Monday
 

Dear yakuza,

I think there won't be problem closing the transfer case, it's the same case for all; but I have to buy a new, different chain, although in the manual was stated that only automatic Jimny owner should buy such chain.

Here is the answer I got from Trail Gear:

" Unfortunately it appears that Suzuki did several different configurations depending on where the model was manufactured. Hey did state that if the stock chain from your vehicle does not fit than you will more than likely need 29225-84A00."