Ola`s jimny project

Ola sent a video to me of his low gear crawl so i am really looking forward to complete mine now.
When putting mine together i had some problems getting the box back together as the 4wd clutch (the one with balls and springs) would not enter properly, and some problems with the shift forks. These problems was that the syncro ring had broke for some reason. The best way to identify problems like this is to test fit the casings with just some of the shafts in there at a time. this way you will see if the casings slide all the way together easily. There are many good tips in the auszookers thread. It is a must to read it before you go at it as the accompanying documentation is lacking some helpful info.
Now i am waiting for the syncro ring to come. Hopefully in time for my trip south to my daughters horse event.

Thanks for that link, it really is well done, the guy must have spent some time putting all that together.

I'll go and redo the bits that he has included but weren't mentioned in the guide that comes with the parts. It almost seems as though the one cog is 1mm too wide so I cant get the bearing to seat in the cup when trying to insert the counter gear. I'm hoping that it's something I've missed and not an issue with the manufacturing (which is unlikely, but after trying for the 25th time your mind starts having doubts!).

I also cant wait to get it finished, have 235s on and am not enjoying the road driving much at the moment. I was also in dire need of a lower low box this weekend, what were Suzuki thinking when they decided on these ratios!

You cannot insert the counter shaft after the low gear wheel have been changed on the main shaft. It is not doable, they must be inserted together like the auszookers recipe says. This info is not in the trailgear docs.
This is where your balls and springs might fly a couple of times..

I found if I put the main shaft and shift fork rods so they just about enter and hold them with one hand, i could stretch over with my other hand for the counter shaft and sneak the bearing past the low gear wheel on the main axle.
Then wiggle them down so the shift forks and clutch rings and everything slips into place.

Venter wrote: Thanks for that link, it really is well done, the guy must have spent some time putting all that together.

I'll go and redo the bits that he has included but weren't mentioned in the guide that comes with the parts. It almost seems as though the one cog is 1mm too wide so I cant get the bearing to seat in the cup when trying to insert the counter gear. I'm hoping that it's something I've missed and not an issue with the manufacturing (which is unlikely, but after trying for the 25th time your mind starts having doubts!).

I also cant wait to get it finished, have 235s on and am not enjoying the road driving much at the moment. I was also in dire need of a lower low box this weekend, what were Suzuki thinking when they decided on these ratios!

Most 4x4 with reduction gearbox have a low ratio of about 2-2.5:1, which works fine if you keep standard tyre size.

yakuza wrote: You cannot insert the counter shaft after the low gear wheel have been changed on the main shaft. It is not doable, they must be inserted together like the auszookers recipe says. This info is not in the trailgear docs.
This is where your balls and springs might fly a couple of times..

I found if I put the main shaft and shift fork rods so they just about enter and hold them with one hand, i could stretch over with my other hand for the counter shaft and sneak the bearing past the low gear wheel on the main axle.
Then wiggle them down so the shift forks and clutch rings and everything slips into place.

That approach sounds promising, will give it a go tonight. Would have pulled my hair out this last weekend (if I had any)!

Tom, thanks for the info, I was wondering how the Jimny compared to other vehicles. I suppose having such small stock tyres means that any increase of a few cm diameter relatively affects the gear ratio more compared to having a starting point of a much larger tyre and increasing by the same number of cm.

First real test of the transfer gears today.. Had a good run in some small river creeks, through tight woods and up/down some banks..

Soo much better to have time to place the wheels correct, and to reduce clutch work by like 300%.. Best mod so far!

The high series also suits the normal driving alot better!