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Grand Vitara transfer Case removal. Gearbox out?
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Author:  Beniblack [ Sun Nov 24, 2019 9:53 pm ]
Post subject:  Grand Vitara transfer Case removal. Gearbox out?
Hi All, Have a vibration when doing 90>110 km/hr I've been chasing, its a very high frequency vibration and can feel it through transfer gearstick, guessing its either Uni Joints or Transfer bearing.. Long story short I have a donor GV with a Transfer and shafts in good condition so want to swap it out.. Can this be done easily without gearbox coming out? ive refered to the workshop manual and its a very brief description but seems it can be done as there is no mention of removing gearbox..

thanks in advance..
Author:  ZUZUKI [ Tue Nov 26, 2019 8:15 pm ]
Post subject:  Re: Grand Vitara transfer Case removal. Gearbox out?
I've not done it to a GV, but a Vitara transfer can be removed with the g/box still in the car & a Vitara & GV are very closely related in in that area, so I don't see why you couldn't.
When doing a Vitara, you have to watch for the distributor hitting the firewall when you drop the g/box xmember & lower the rear of the engine - there is more clearance at the back of a 2.5L (no dist. for a start!) but just watch for cam sensors & wiring in that area.
Rgs, Michael
Author:  shakes [ Thu Nov 28, 2019 12:44 pm ]
Post subject:  Re: Grand Vitara transfer Case removal. Gearbox out?
Can be done 'easy' enough.

Top bolts need some creative thinking.

Do some searching on here, there was a minor TC recall at some stage to do with it popping out of 4h.
I also had an easily replaceable (internal) cir-clip break taking out my shift linkage.

Have you checked all gearbox and diff mounts etc are tight and in good condition? mine were super loose.
Author:  Beniblack [ Mon Dec 02, 2019 5:01 pm ]
Post subject:  Re: Grand Vitara transfer Case removal. Gearbox out?
Hey guys, thanks for replies.. I've got both gearsticks out and shafts & exhaust off ready for an attempt when I get a day off.. The transfer in new GV (2002) definitely has a vibration coming from output shaft to rear diff, uni joints feel ok with a quick inspection, mounts & rubbers look OK.. But if I wobble the out put shaft/yoke back and forth I can definitely feel slop like moves about 5mm so am guessing that's the source of most the vibration. I know my other donor GV (2002) Transfer and front diff are in good shape as it hadn't done any off roading since new when previous owner bought the car. She'd never used 4x4.. Just towed a dog trailer.. Over Xmas break I'm swapping most the drive line including front diff.. Also I'm thinking rear axle bearing or rear diff a bit suss also, I changed oil and it was almost empty and what came out was not pretty.. So vibration or part of could be rear axle or diff, it also wines quite a bit and rumble from rear. Will swap the lot I think..
Thinking transfer should come out without to much drama but as mentioned it's the unknown top bolts I could struggle with..
Thanks again. Should be a lot of fun.. lol..
Author:  Beniblack [ Wed Dec 11, 2019 7:41 pm ]
Post subject:  Re: Grand Vitara transfer Case removal. Gearbox out?
Crikey.. Those Top bolts.. Any tips? I'm thinking gearbox has to come out at this point..
Author:  shakes [ Thu Dec 12, 2019 6:19 pm ]
Post subject:  Re: Grand Vitara transfer Case removal. Gearbox out?
16 extension bits, some uni's and some luck.
and you need double jointed elbows and wrists. Plus your tongue has to be in the correct position.
Author:  Beniblack [ Tue Dec 24, 2019 8:43 pm ]
Post subject:  Re: Grand Vitara transfer Case removal. Gearbox out?
Well I've done a mod.. Cut small hole in LH gearbox arch, had boxTransfer out In no time.. Put nutserts in & a plate & sealant.. Job done.. Worthwhile mod I reckon.
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