[just_cruizin]

I have a 2004 GV and would like to know more about fitting transfer case gears, problem is Low range only have gears to suit 2001 and before, apparently Suzuki changed the design due to the earlier cases jumping out of gear.

My question is will the early model transfer fit my 2004 or could I fit just the front half of the case?

[Built4thrashing]

The earlier transfer cases will bolt up to the later gearboxes and vice-a-versa.

The transfer gears will only change low range. High range is not altered.

Have you explored diff ratios options?......

[just_cruizin]

Not as yet, probably the best option as ill have to change to vit diff centers if or when lockers are the go and to get rid of the auto engaging front

[Built4thrashing]

just_cruizin wrote:

Not as yet, probably the best option as ill have to change to vit diff centers if or when lockers are the go and to get rid of the auto engaging front

I'd be swapping to 5.12 diffs first and get rid of the stupid air engagement front.... Quite a simple job to do.

[zoukshin]

b4t, was told by a friend who is rebuilding an old cruiser with commodore bits (yeah I know, it starts off well) that modifying diffs has a lot of consequences.
Apparently it's an art to recync all the gears to have your diff working properly after changing gears or rebuilding them.
Can you elaborate ?

[fordem]

I know of no issues resyncing gears when rebuilding diffs - just don't mix & match - if you replace one you replace all.

Having said that - setting up the ring & pinion (which technically speaking, is not a part of the differential) does require a fair degree of experience.

[Built4thrashing]

Ive done several diff rebuilds now and ive never had any issues.

The Front diff in the GV has been stripped and had the internals changed.

Steel housing and carrier, Vitara internal hemisphere and GV 4.8 ring and pinion with a 1510 Sierra Lockright.

No weird noises or problems as yet and its been fitted for3 years and 20,000kms so far.


You just have to make sure you use matching R&P. and everything is in good order. (not worn out)