[parfittron]

Hey guys,

I have a 2006 (push button transfer) jimny that I have been having a fair bit of trouble engaging into 4wd, currently I am unable to engage it at all.

I think it is a combination of problems (leaking hub seals, meaning their was some corrosion from water in the hubs but I couldn't find a vac issue thus far.

I was curious about exactly what replacement hubs (from what models etc) I can use to swap over to some manual locking ones.

I have possibly sourced a set of old sierra ones, but will they actually fit? If they will, what else am I required to do to trick the electronic case into engaging without the vacuum hubs?

Thanks for the help
Chris

[lordviper556]

i got an 04 jimny and i put manual hubs on it. i just rang a wrecker and got some sierra hubs, idk what model they were off.

you also need to do is get some 10mm thick spacers made up and get some longer bolts (the jimnys are to short and the sierras are to long or vice versa) and your set.

all you need to do to fit them is take the old hubs off (u will need a special torx socket, T10 i think it is) and then put the spacers on and then the hub, bolt it up and bobs ur aunty. took me about 1/2hr all up including cleaning and regreaseing the sierra hubs. i used a bit of the loctite gasket goo stuff on both sides of the spacer to make sure nothing go in.

let us know if you need any more help.

[parfittron]

What part exactly are you 'spacing'?

Also, the push button 4wd (I don't believe the 04's had that) means that to engage the transfer, the vacuum must have successfully locked the hubs as part of that.

Any idea how do I trick it into doing so?

[zukenutter]

Bugsta has manual hubs on his 2009 jimny. I don't think there was anything he needed to do to trick the tcase. I'm pretty sure it,s electronically actuated. When the hubs are installed your 4wd light will flash, a small price to pay.

[parfittron]

I thought I may have to seal the ends of the back lines. I also am not sure if this will actually solve the problems I'm having.

[lordviper556]

i never touched the lines on mine and i dont have any problems with the flashing 4wd light. i read on another forum all you need to do to fix the flashing light is take the battery off for a while to reset the computer. idk if it works or not.

there is a lip that sticks out of the hub assy that seals inside the auto hubs, the manual hubs dont have this so you need to use a spacer to get the manual hubs to fit. if you have a lathe you could also machine the inside of the manual hubs to suite, but i reckon the spacers would still be easier.

[bluejim]

I've got a 2007 with manual locking hubs and a welded front diff. I engaged 4wd and the light flashs. Now i can't get it back into 2wd. I press the button but nothing happens. Any ideas fellas?

[steak_knife]

bluejim wrote:

I've got a 2007 with manual locking hubs and a welded front diff. I engaged 4wd and the light flashs. Now i can't get it back into 2wd. I press the button but nothing happens. Any ideas fellas?

Rocking the car forward & back may help..
Did you disconnect the vacuum module when fitting the man hub's??
Did you drive it in 4wd??

[89_tintop]

grave dig..

any pics of the spacers required? and who made them.

[zukenutter]

I've just swapped over to my new Jimny which is push-button and have found the following;
- Sometimes it engages straight away
- Sometimes it doesn't
I've not figured out yet what sequence, if any, works best.
If it flashes when selecting 4H the case has not shifted, L4 won't work at this point. The best fix seems to be either or both of;
- Turn ignition off, wait a few seconds and turn on again. Same goes for switching back to 2H
- Go forward and backward a bit

I've not tried blocking airlines yet but will be swapping in my stick shift case shortly anyway.

The spacers for manual hubs are available through bigjimny.com

[lordviper556]

89_tintop wrote:

grave dig..

any pics of the spacers required? and who made them.

i got mine made up at a local engineering shop, cant remember how much $50 or something I think.

this link has a few pics and info on how to do the whole conversion. I just took the sierra hubs into the shop and they measured them up and I drilled the holes at home. there is a small taper on the inside of the sierra hubs thats what they used for the inside diameter.

http://www.bigjimny.com/images/document ... l_hubs.pdf

i forgot, you will need a T10 torx bit to undo the stando jimny hubs.

[zukenutter]

lordviper556 wrote:

89_tintop wrote:

grave dig..

any pics of the spacers required? and who made them.

i got mine made up at a local engineering shop, cant remember how much $50 or something I think.

this link has a few pics and info on how to do the whole conversion. I just took the sierra hubs into the shop and they measured them up and I drilled the holes at home. there is a small taper on the inside of the sierra hubs thats what they used for the inside diameter.

http://www.bigjimny.com/images/document ... l_hubs.pdf

i forgot, you will need a T10 torx bit to undo the stando jimny hubs.

Or an 8mm socket will often get enough grip on the Etorx head.

[bluejim]

steak_knife wrote:

bluejim wrote:

I've got a 2007 with manual locking hubs and a welded front diff. I engaged 4wd and the light flashs. Now i can't get it back into 2wd. I press the button but nothing happens. Any ideas fellas?

Rocking the car forward & back may help..
Did you disconnect the vacuum module when fitting the man hub's??
Did you drive it in 4wd??

I didn't disconnect the vacuum mod and it worked fine in 4wd. But I couldn"t shift to low range as the light is just flashing. So now I'm driving around with the hubs unlocked but the 4wd is still turning the driveshaft. Would it be worth while blocking the vac hoses to trick the t case? And what is the best way to do it?

[zukenutter]

don't know, haven't looked at it yet. Has yours worked in the past, or did this fail happen first time out?

[BertZook]

any one knows about the suzisport kits?

[89_tintop]

BertZook wrote:

any one knows about the suzisport kits?

got a link mate?

[BertZook]

http://www.suzisport.com/shop/

there is no direct link, but look for it in the performance tab and jimny

[kemlar]

Thinking about doing the manual hub swap now. Does it really play up that much and not go into 4 low?, or is it just the light not working? Also does anyone know anyone on the sunshine coast that has made the spacers before that I could go to for mine?

[zukenutter]

kemlar wrote:

Thinking about doing the manual hub swap now. Does it really play up that much and not go into 4 low?, or is it just the light not working? Also does anyone know anyone on the sunshine coast that has made the spacers before that I could go to for mine?

Definitely not engaging 4wd. I think it flashes whenever the hub vacuum is not at the required pressure, whether you're in 2wd or 4wd. Has not failed to engage or disengage properly yet but takes a few attempts.

[Taylor74]

Check the switch on the front of the transfer before you go hubs.
The wires get caught and damaged then 4wd becomes null and void. The computer need this to engauge the hubs. Its the most front switch on the transfer. If you are getting free wheel hubs why dont you get Vitara hubs and machine the lip on the hub nut of for the vacum feed into the hubs. That way you dont need spacers and keep you hubs further inside the wheel offset.

[kemlar]

Do you have the manual hubs on your new rig zukenutter? Or are you just having problems with the push button transfer? Have you tried enagaging it on the move, may not be pressure just chain drive in transfer in a wierd spot or something. Only guessing, cause my mates one without the manual hubs and push button transfer sometimes does that.

[zukenutter]

Mine worked perfectly before the swap to manual hubs, wasn't too worried because I knew I'd be swapping to a lever transfer anyway.

Taylor74's suggestion will work just as well as using a spacer for fitting unless you plan on possibly switching back to the auto hubs because once the lip is removed the auto hubs won't work. For me $60 meant I could switch back whenever I wanted.

[kemlar]

Was it hard to order off the big jimny website? Also do you have to use a used hub from a vitara or sierra, or can you buy new Warn hubs or something?

[zukenutter]

kemlar wrote:

Was it hard to order off the big jimny website? Also do you have to use a used hub from a vitara or sierra, or can you buy new Warn hubs or something?

Can't see why it couldn't work with any Sierra or Vitara hub. BigJimny were easy to deal with.

[Benz]

I wont be swapping mine until they break.

but..

when they do I now know what to do.

thanx =]

[zukenutter]

There's really no advantage to having them. I wanted to be able to use low range while parking the trailer so I don't have to work the clutch so much.

[lordviper556]

i put them on mine casue after i did the lift and fitted the tyres i only had 2wd. i couldnt be bothered trying to fix the problem i just went straight to manual hubs. i think it was worth the effort, i never have to worry about my hubs unlocking at a really bad time.

[kemlar]

One last thing I am wanting to know on this post question.. When I install the manual hubs and I already have the Sierra case in..
Am I able to remove all the air hub lines and associated things?
And also I am aware that there may be something needed for the 4WD light to work properly, or maybe I can just wire it like a switch cause I have the sierra case and will have manual hubs in?

[bluejim]

I did the ignition on off thing and it worked it takes a few trys though. Sometimes the light flashes but to get into 4L the light must be on. Maybe there is a combination but I haven't worked it out yet. I also looped the vac lines at the point where the two sides meet but I don't know if that had any effect.

[zukenutter]

Seem to have sorted this today. Yay. Was the first time I've actually decided to play with it. Very easy to sort out. You need to remove the two hoses that come from the engine bay and just screw a tight fitting screw into both so the result being the lines from the engine bay are terminated. Do the same to the lines at the axle end to stop shit getting into your hubs and your done, transfer case is tricked and will engage as it should.

bluejim wrote:

I did the ignition on off thing and it worked it takes a few trys though. Sometimes the light flashes but to get into 4L the light must be on. Maybe there is a combination but I haven't worked it out yet. I also looped the vac lines at the point where the two sides meet but I don't know if that had any effect.

Looping won't worked, tried it. The lines need to be blocked