Transfer box conversion to Rock Lobster - Revision history

Mlines: /* What is needed */

2019-12-20T19:17:43Z

What is needed

Bosanek: Category adjustment

2019-02-21T14:32:10Z

Category adjustment

X88RED at 13:10, 24 May 2018

2018-05-24T13:10:16Z

Bosanek: Added a note about needing and choosing a proper oil

2018-05-24T11:11:23Z

Added a note about needing and choosing a proper oil

Bosanek: Adjusted the sizes of all the pictures in the article

2018-01-15T11:07:08Z

Adjusted the sizes of all the pictures in the article

Bosanek: Minor adjustments

2017-12-27T15:51:00Z

Minor adjustments

Bosanek: Minor adjustments

2017-12-27T15:46:28Z

Minor adjustments

Bosanek: Minor adjustments

2017-12-27T15:43:15Z

Minor adjustments

Bosanek: Removed the temporary intro note

2017-12-27T14:43:32Z

Removed the temporary intro note

Bosanek: Completed the transfer of all the pictures from the original old PDF guide. The copy is now complete.

2017-12-27T14:40:42Z

Completed the transfer of all the pictures from the original old PDF guide. The copy is now complete.

Show changes

@@ Line 77: / Line 77: @@
 |Output Shaft Front Bearing
 |08173-63060
-|6308N from SimplyBearings
+|6306N from SimplyBearings
+|
 |-
@@ Line 193: / Line 193: @@
 You will need to ensure that you have the correct flange sizes on the new transfer box to match your propeller shafts. They can be swapped over.
 == The work ==

@@ Line 455: / Line 455: @@
 End of the guide.
 {{Edited}}
 [[Category:Howto]][[Category:Drivechain]][[Category:Modifications]]

← Older revision		Revision as of 13:10, 24 May 2018
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	When everything is complete, you will need suitable oil for the new shiny Rock Lobster transfer box. Use a (monograde) SAE EP90 transmission oil (that is what Suzuki originally recommended for use in SJ transfer boxes). It should not really matter if it is classified as API GL-4 or GL-5, as there are no "yellow metals" inside the transfer box. If you can't find a monograde SAE 90 oil, then a multigrade SAE 80W-90 oil should also suit OK. It might prove to be slightly less thick, causing a bit increased gear noise from the transfer box.		When everything is complete, you will need suitable oil for the new shiny Rock Lobster transfer box. Use a (monograde) SAE EP90 transmission oil (that is what Suzuki originally recommended for use in SJ transfer boxes). It should not really matter if it is classified as API GL-4 or GL-5, as there are no "yellow metals" inside the transfer box. If you can't find a monograde SAE 90 oil, then a multigrade SAE 80W-90 oil should also suit OK. It might prove to be slightly less thick, causing a bit increased gear noise from the transfer box.
−	Required quantity of oil is ~~currently unknown - someone should add that info here - but it is probably slightly above 1 l~~.	+	Required quantity of oil is 1l exactly.

← Older revision		Revision as of 11:11, 24 May 2018
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	</font>		</font>
	</big>		</big>
		+
		+
		+	When everything is complete, you will need suitable oil for the new shiny Rock Lobster transfer box. Use a (monograde) SAE EP90 transmission oil (that is what Suzuki originally recommended for use in SJ transfer boxes). It should not really matter if it is classified as API GL-4 or GL-5, as there are no "yellow metals" inside the transfer box. If you can't find a monograde SAE 90 oil, then a multigrade SAE 80W-90 oil should also suit OK. It might prove to be slightly less thick, causing a bit increased gear noise from the transfer box.
		+	Required quantity of oil is currently unknown - someone should add that info here - but it is probably slightly above 1 l.

@@ Line 195: / Line 195: @@
 === Disassembly ===
-[[File:Transfer box conversion to Rock Lobster guide - figure 01.png|thumb|left|480px|Figure 01 - removing the shifter]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 01.png|thumb|left|272px|Figure 01 - removing the shifter]]
 * First you have to get both transfer boxes onto the workbench.
@@ Line 225: / Line 225: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 05.png|thumb|left|480px|Figure 05 - removing the speedo drive]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 05.png|thumb|left|488px|Figure 05 - removing the speedo drive]]
 * Now remove the speedometer driven gear.
@@ Line 244: / Line 244: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 07.png|thumb|left|480px|Figure 07 - removing the front of the transfer case]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 07.png|thumb|left|464px|Figure 07 - removing the front of the transfer case]]
 * Now take off the front section of the transfer case.
@@ Line 250: / Line 250: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 08.png|thumb|left|480px|Figure 08 - splitting the case]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 08.png|thumb|left|448px|Figure 08 - splitting the case]]
 * Now undo the bolts that hold the centre and rear cases together.
@@ Line 259: / Line 259: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 09.png|thumb|left|480px|Figure 09 - removing the shift fork spring]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 09.png|thumb|left|288px|Figure 09 - removing the shift fork spring]]
 * Using a pin driver (or old nail!), drive out the pin on the shift fork on the main gear side of the transfer box.
@@ Line 268: / Line 268: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 10.png|thumb|left|480px|Figure 10 - removing the output shaft]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 10.png|thumb|left|248px|Figure 10 - removing the output shaft]]
 * At this point you will be able to tap the output shaft out of the case.
@@ Line 276: / Line 276: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 11.jpg|thumb|left|480px|Figure 11 - intermediate gears (410 LEFT, 413 RIGHT)]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 11.jpg|thumb|left|640px|Figure 11 - intermediate gears (410 LEFT, 413 RIGHT)]]
 * The intermediate shaft is now free to be removed.
@@ Line 292: / Line 292: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 12.jpg|thumb|left|480px|Figure 12 - painted transfer case]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 12.jpg|thumb|left|640px|Figure 12 - painted transfer case]]
 * Whilst the gears are off being cut and shut you can busy yourself preparing the rest of the box.
@@ Line 299: / Line 299: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 13.jpg|thumb|left|480px|Figure 13 - comparing the two output shafts]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 13.jpg|thumb|left|640px|Figure 13 - comparing the two output shafts]]
 * You also need to combine the gears from the 410 output shaft and the 413 output shaft to create a new Rock Lobster output shaft.
@@ Line 317: / Line 317: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 15.jpg|thumb|left|480px|Figure 15 - gears before welding]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 15.jpg|thumb|left|352px|Figure 15 - gears before welding]]
 * By now you should have also built your replacement intermediate gear.
@@ Line 325: / Line 325: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 16.jpg|thumb|left|480px|Figure 16 - gears after welding]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 16.jpg|thumb|left|752px|Figure 16 - gears after welding]]
 * This picture shows the welded gears.
@@ Line 339: / Line 339: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 17.jpg|thumb|left|480px|Figure 17 - bearing puller]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 17.jpg|thumb|left|500px|Figure 17 - bearing puller]]
 * If you are changing the bearings you need to pull out the old bearings and push on the new.
@@ Line 350: / Line 350: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 18.png|thumb|left|480px|Figure 18 - driving out the shaft]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 18.png|thumb|left|368px|Figure 18 - driving out the shaft]]
 * The front case bearing is more hidden.
@@ Line 359: / Line 359: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 19.jpg|thumb|left|480px|Figure 19 - front case bearing]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 19.jpg|thumb|left|672px|Figure 19 - front case bearing]]
 * Putting the new bearing in requires some care.
@@ Line 382: / Line 382: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 20.jpg|thumb|left|480px|Figure 20 - input shaft in position]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 20.jpg|thumb|left|672px|Figure 20 - input shaft in position]]
 * First of all insert the input shaft on its own.
@@ Line 404: / Line 404: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 21.jpg|thumb|left|480px|Figure 21 - all shafts in position]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 21.jpg|thumb|left|672px|Figure 21 - all shafts in position]]
 * First build the input Shaft onto the middle case section.
@@ Line 413: / Line 413: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 22.jpg|thumb|left|480px|Figure 22 - you did include the shift fork when putting the output shaft!]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 22.jpg|thumb|left|672px|Figure 22 - you did include the shift fork when putting the output shaft!]]
 * Remember to include the shift fork as you put the output shaft in place.
@@ Line 420: / Line 420: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 23.png|thumb|left|480px|Figure 23]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 23.png|thumb|left|376px|Figure 23]]
 * Now the two cases can be recombined.
@@ Line 434: / Line 434: @@
 <br clear=all>
-[[File:Transfer box conversion to Rock Lobster guide - figure 24.jpg|thumb|left|480px|Figure 24 - welding up the speedo drive]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 24.jpg|thumb|left|752px|Figure 24 - welding up the speedo drive]]
 * If you are building the Transfer Case for an SJ you will need to reinsert the speedometer drive at this point.
@@ Line 444: / Line 444: @@
-[[File:Transfer box conversion to Rock Lobster guide - figure 25.jpg|thumb|left|480px|Figure 25]]
+[[File:Transfer box conversion to Rock Lobster guide - figure 25.jpg|thumb|left|752px|Figure 25]]
 * Now replace the flanges and drum brake assembly (if required).
 * Stand back and admire your work.

@@ Line 370: / Line 370: @@
 * Now to re-assemble the gearsets.
 * The factory manual spends a lot of time discussing “end float” and how it should be set correctly.
@@ Line 385: / Line 379: @@
 * However, Richard Wattam told me a sneaky technique.
 * This involves a bit of work assembling and dismantling the case, but it works.
 * First of all insert the input shaft on its own.
-** Assemble (and bolt together) the case WITHOUT a gasket and check how the shaft turns.
+* Assemble (and bolt together) the case WITHOUT a gasket and check how the shaft turns.
-** If it is stiff then it is fine and no shims are needed.
-** If it turns freely then disassemble and add a shim.
-** Rebuild the case and see if the shaft becomes stiff to turn.
+* If it is stiff then it is fine and no shims are needed.
-** Once it does then it is correctly shimmed.
+* If it turns freely then disassemble and add a shim.
 * Now you can move on to the output shaft.
-** Again, repeat the process with only the output shaft and WITHOUT the gasket.
+* Again, repeat the process with only the output shaft and WITHOUT the gasket.
-** Keeping adding shims until the output shaft is stiff to turn.
+* Keeping adding shims until the output shaft is stiff to turn.
 * This process works because you have not fitted the gasket.
 * Once it is fitted it adds the correct spacing!
 * First build the input Shaft onto the middle case section.
 * I found the input shaft difficult to insert.
 * In the end I refitted the flange and tightened the flange nut to pull the gearset into position.
-* Then fit the intermediate shaft and finally the output shaft
+* Then fit the intermediate shaft and finally the output shaft.
 * Remember to include the shift fork as you put the output shaft in place.
-** There is not enough room to add it afterwards!
+* There is not enough room to add it afterwards!
 <br clear=all>

@@ Line 368: / Line 368: @@
 <br clear=all>
 [[File:Transfer box conversion to Rock Lobster guide - figure 20.jpg|thumb|left|480px|Figure 20 - input shaft in position]]
@@ Line 374: / Line 377: @@
 [[File:Transfer box conversion to Rock Lobster guide - figure 22.jpg|thumb|left|480px|Figure 22 - you did include the shift fork when putting the output shaft!]]
 * The factory manual spends a lot of time discussing “end float” and how it should be set correctly.
@@ Line 419: / Line 419: @@
 * Squirt some gearbox oil over the bearings and moving parts to help everything when it spins up for the first time.
 * The cases should then push together with a firm push.
@@ Line 429: / Line 428: @@
 * If you are building the Transfer Case for an SJ you will need to reinsert the speedometer drive at this point.
-* However, if you are building it for a Jimny, then you will have no need for the mechanical drive.
+* If you are building it for a Jimny, then you will have no need for the mechanical drive.
 * However you will need to put something in to stop it leaking oil.
 * I simply took the SJ speedo mount and welded up the end and silicon gasket sealed it into place.
@@ Line 441: / Line 440: @@
 <br clear=all>
 {{Edited}}
 [[Category:Howto]][[Category:Drivechain]][[Category:Modifications]]

@@ Line 253: / Line 253: @@
 * Now undo the bolts that hold the centre and rear cases together.
-* Do not undo the bolt marked "I" in the picture.
+* Do not undo the bolt marked "1" in the picture.
 * When you split the cases, be careful of the shims that will fall off the shafts.
 * Make a note of where the shims came from.
@@ Line 356: / Line 356: @@
 * Using a soft mallet you can then drive out the shaft.
 * It will then be possible to drive the old bearing out from behind.
 <br clear=all>
 [[File:Transfer box conversion to Rock Lobster guide - figure 19.jpg|thumb|left|480px|Figure 19 - front case bearing]]
 * At this point, with all the bearings changed, you can fit new oil seals if required.

← Older revision		Revision as of 14:43, 27 December 2017
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	== Introduction ==		== Introduction ==
−
−
−	{{note\|Тhis wiki article is an unfinished copy of the original old BigJimny PDF guide. <br> All the text has been copied with minimal adjustments, but all the pictures are missing. <br> Someone needs to add the original pictures to make it a complete copy.}}