Hi guys,
As some of you jimny owner's know, Off Road Armoury have released a new transfer case conversion kit. As this kit was only released last week, there is no information on how to install the kit. Here is the write for the install for the 1st version of the ORA conversion kit http://www.bigjimny.com/images/document ... mounts.pdf This is the most detailed write up i have for the 1st version of the kit, most of which still apply's to the new kit.
Any way, here is my write up on how to install the new kit.
Parts required:
x1 SJ wide track transfer case
x1 Front wide track drive shaft
x1 wide track jack shaft (gear box to transfer case)
x1 ORA conversion
x1 Set of SJ free wheeling hubs with adapter rings
Tools required:
-12, 14, 17 and 27mm sockets
-10, 12, 14 and 17mm open end spanner's
-Long nose pliers (for undoing electrical clips
)Misc.
-oil ( I used VMX 80w-90)
x12 drive shaft bolt's and nut's ( i used all the original sierra drive shaft bolts)
- Press ( or oven and freezer)
- Oxy ( or big hammer)
Step 1: Remove the out put flange on the back of the sierra transfer case. Best way to get this off, is with a heavy duty rattle gun. If you don't have access to a rattle gun, get a peace of flat bar 1000mm+, drill 2 hole's into the flat bar the same distance apart as what they are on the flange. From memory that is 60mm and the hole size 12mm, then bolt the flat bar into the flange. Then get a 27mm socket with a break bar, and then crack the nut. If you are finding it very hard to crack, get a peace of pipe and slip of the breaker bar to add more leverage making it easier to crack the nut.
Step 2: Once the flange has been removed, you need to knock the backing cup off.
This can be done with a hammer or it can be cut off. The flange should then look like this.
Clean the flange up with a wire wheel removing any surface rust then paint to your colour of choice.
Step 3: Now the speedo wheel needs to be put on the flange.
There are several ways of putting the wheel on. The best optoin is to get it pressed on. If you don't have access to a press, another optoin is to put the flange in the freezer for a few hours to contract the size of the flange. While the flange is freezing, the ring gear needs to be put into the oven to expand it. Once the flange has contracted and the ring has expanded, slip the ring gear over the back of the flange. Work fast though, you don't want either item going back to it's original size while the ring is half way on!!!
Step 4: Next the transfer case mount needs to be bolted on while the flange is off, like so:
Step 5: Now the rear out put flange can be put back. Make sure the bolt is tight to!!!
Step 6: Now the speed sensor can be put on. This part with will need to be removed from the jimny t-case as seen here:
Once removed you will need to find a nut & bolt to suit the hole size. There is also a rubber o-ring that needs to be removed. Once that is done is can be put onto the t-case mount.
It needs to be tapped down lightly with a hammer unti it's hard up on the mounting face, as it's a very "Snug" fit.
Step 7: Once the jimny transfer, jack shaft and rear shaft have been removed, you can then put the WT jack shaft into the gear box and bolt the rear tail shaft to the rear diff ( Hint: Park the car with the back end higher than the front to stop oil coming out of the back of the gear box
)Step 8: The transfer can now be put into the car. Rest the 2 mount's on the chassis and the other side on the exhaust. The small bush goes on top of the mount with a washer, the larger one in the middle then the bolt from the bottom up. Like so:
Don't do these bolt's up yet.
Step 9: Now the other side mount can be put on. The poly mount's go on in the same order as the other side does. The mount can also be bolt onto the t-case now.
Step 10: Now all the drive shaft's can be bolted back onto the transfer case. Best not to do the mount's up yet as the rear tail shaft was a tight fit. Once all the drive shaft bolt's are tight the mount's can be do up at the same time.
Step 11: The transfer case can now be filled it oil and the speedo sensor cable can be connected back up at the same time.
Step 12: The transfer case stick now needs to be bent to clear the hole in the floor. As you can see there is not a lot of room in there.
IMO the best way to get the best position for the stick, is to heat it with a oxy, make it straight & start from scratch then bend to suit. I have not done this part yet, but once i have done it tomorrow i will upload a picture.
Other notes:
- 4wd light flashes. I beleave the fix is just to join a few wires together. Once i have figured out which one's i will share my finding's
- The vacuum's hubs can be rigged up to work with the SJ case. All that is needs to be done make this work is a switch at one of electrical joiner's. I did have it working, but didn't rig up a switch because i ran out of day light. This will allow you have have 2wd low range with out getting out of your car
If i have missed any thing or you need any more info, please ask and i will help where i can.
Hope this helps someone!
Cheers,
Monley
nice work monkey
I'm going to try the jimny sensor again later this arvo.
Job for the weekend 