[zukenutter]

I've been working on swapping the gearbox and transfer in my 2006 VVT Jimny for a non VVT box and Sierra (Samurai) transfer. Have had a few issues with swapping the gearbox, but all in all has worked out quite well. The on-road driving is great, with the ratios giving me roughly a 6% drop in final to-the-road gearing.
The transfer swap was really easy with the ORA kit I purchased except the 2nd hand transfer needed attention. With the help of a mate we (he) rebuilt my transfer. Unfortunately the rebuild kit I bought, with no knowledge of them, turned out to not include the counter shaft and thrust washers. My mate machined a shaft from 1" hardened rod and I reused the old thrust washers. Same noise has returned after 3 hours of running, so I've bought the final parts to a complete overhaul and will install them on Monday.

Transfer out. I removed the middle section of the exhaust to help the gearbox clear everything. Installed a new clutch to suit NON VVT Jimny while it was apart.



Shifter boot is unbolted



Jimny electric on right



Jimny electric on Left






The complete driveline that's going in



Pulled the gearbox, compared it to new and realised that there was going to be some shift mechanism issues. As it turned out the rear gearbox mount is different so I used the Mark III Jimny mount but had to re-drill a couple of holes.

Both gearboxes are very different.

Mark III back, Mark II front




Reverse sender plug wasn't compatible so RC parts to the rescue.



Transfer mounted




I need to make a mount for the shifter mech.



Progressed with the gear shifter support and will finish it tomorrow.




Will tighten this support with a couple of large inner diameter washers, makes shifting gear much more precise, well I like how it feels.



Shifting into 3rd and 5th was gone again last time I drove it, opened the base plate and found the missing shift bush getting caught-up in there.




The transfer is back out for some new thrust washers and a new counter shaft.

Sierra transfer "on the bench"

[Rusho]

Excellent work mate

[zukenutter]

Cheers

I split the rear of the case today, replaced the counter shaft and thrust washers and bolted it all back together.

With a bit of luck that's it. The test drive was great, and quiet, especially now that I've remounted the gearbox shifter. I'll give it a longer run tomorrow.

[cunneen]

Looks like a big job, Well done though!

Is it possible to use a Samurai transfer with a VVT box or would the gearing be way out off whack ?

[steak_knife]

I'd just like to add, if you have extractor's with out a flange at the cat & are planing to take the g/box out, go to an exhaust shop & get one fitted..(flange)
Cat need's to come out to remove g/box & won't fit out if glued to the extractor's....

[zukenutter]

steak_knife wrote:

I'd just like to add, if you have extractor's with out a flange at the cat & are planing to take the g/box out, go to an exhaust shop & get one fitted..(flange)
Cat need's to come out to remove g/box & won't fit out if glued to the extractor's....

What he said ^^^^^^^

cunneen wrote:

Looks like a big job, Well done though!

Is it possible to use a Samurai transfer with a VVT box or would the gearing be way out off whack ?

The VVT gearbox is 20-30% lower than the Non VVT. If you plan on big tyres a Jimny lever operated transfer will bolt straight in, except for a custom intermediate shaft, and give you a 30% reduction. If you put a Sierra 1.3 you'll get a 40% reduction and a 1.0 Sierra transfer would be 50%. These percentages are roughly calculated and apply to high and low.

Hope that helps.

[cunneen]

Quote:

The VVT gearbox is 20-30% lower than the Non VVT. If you plan on big tyres a Jimny lever operated transfer will bolt straight in, except for a custom intermediate shaft, and give you a 30% reduction. If you put a Sierra 1.3 you'll get a 40% reduction and a 1.0 Sierra transfer would be 50%. These percentages are roughly calculated and apply to high and low.

Hope that helps.

So basically there is no sierra/Samurai transfer case that I can use with the VVT gearbox and still have similar ratio's at the end.

Is that right? just want to get rid of the chain drive vvt set-up

[zukenutter]

cunneen wrote:

Quote:

The VVT gearbox is 20-30% lower than the Non VVT. If you plan on big tyres a Jimny lever operated transfer will bolt straight in, except for a custom intermediate shaft, and give you a 30% reduction. If you put a Sierra 1.3 you'll get a 40% reduction and a 1.0 Sierra transfer would be 50%. These percentages are roughly calculated and apply to high and low.

Hope that helps.

So basically there is no sierra/Samurai transfer case that I can use with the VVT gearbox and still have similar ratio's at the end.

Is that right? just want to get rid of the chain drive vvt set-up

Correct

[zukenutter]

[zukenutter]

Update on the new set-up.

Have had a chance to run it a bit now and am loving the ratios for around town, highway is also good but top speed will be slightly lower. Haven't towed with it yet but can tell it's going to be well suited. The transfer still needs some repair but it's getting close. When the transfer was apart I removed the detent ball so I can select 2 low for trailer parking duties and I have figured out the method for shifting with a single stick.

All up I'm quite pleased with the outcome.

[monley]

I'm about to do the swap next week Mr nutter, but i have 2 questions:

A) Dose the sierra t-case stick need bending at all to clear the floor? Or is it all sweet?

B) What boot did you use around the t-case stick? One from a jimny with a stick or a sierra boot?

[zukenutter]

monkey wrote:

:hey:

I'm about to do the swap next week Mr nutter, but i have 2 questions:

A) Dose the sierra t-case stick need bending at all to clear the floor? Or is it all sweet?

B) What boot did you use around the t-case stick? One from a jimny with a stick or a sierra boot?

A) Needs bending

B) Jimny stick boot

[monley]

zukenutter wrote:

monkey wrote:

:hey:

I'm about to do the swap next week Mr nutter, but i have 2 questions:

A) Dose the sierra t-case stick need bending at all to clear the floor? Or is it all sweet?

B) What boot did you use around the t-case stick? One from a jimny with a stick or a sierra boot?

A) Needs bending

B) Jimny stick boot

Not what i wanted to hear

Any idea where i can get a jimny boot from?

[zukenutter]

monkey wrote:

zukenutter wrote:

monkey wrote:

:hey:

I'm about to do the swap next week Mr nutter, but i have 2 questions:

A) Dose the sierra t-case stick need bending at all to clear the floor? Or is it all sweet?

B) What boot did you use around the t-case stick? One from a jimny with a stick or a sierra boot?

A) Needs bending

B) Jimny stick boot

Not what i wanted to hear

Any idea where i can get a jimny boot from?

Keep an eye out here http://auszookers.com/forum/viewforum.php?f=7 or on ebay

[bcgal0004]

Hey ive got everything only need those 2 shafts. what are the 2 shafts needed from the WT SWB sierra?

shaft from transmission to transfer case
shaft from case to front diff?

cheers

[zukenutter]

bcgal0004 wrote:

Hey ive got everything only need those 2 shafts. what are the 2 shafts needed from the WT SWB sierra?

shaft from transmission to transfer case
shaft from case to front diff?

cheers

Sierra intermediate shaft
Sierra front drive shaft (used to replace the rear shaft on the Jimny)

[zammit]

hey i have a g13bb jimny. im going to chuck 235s on it for the time being. i also have a sierra transfer and shafts. will the ratios be the same as your ratios or are g13bb gear boxes different final drive?

[monley]

zammit wrote:

hey i have a g13bb jimny. im going to chuck 235s on it for the time being. i also have a sierra transfer and shafts. will the ratios be the same as your ratios or are g13bb gear boxes different final drive?

Different final drive again. You need 4.16's t-case gears....

Also, here is my write up on how to install the new version of the ORA kit.

viewtopic.php?f=17&t=30820&p=562605#p562605

[zukenutter]

Swapped back to the bushes supplied by ORA for the Sierra Transfer swap. I'd been running the OEM Suzuki ones for about six weeks to see if I liked them better. I can now confirm that the ORA urethane bushes transfer a lot of transfer noise into the interior. I'll swap back to genuine Suzuki rubber mounts tomorrow, definitely better although the transfer tends to move around more... probably a good thing anyway.