[aaronstevens]

As a lot of you may be aware GV 98,99 have a problem with jumping out of 4H and clunking in 4L, have came to the conclusion that it is in the transfer case.
Does anyone have any info on rebuilding or switching out and changing the transfer case in my SQ420 GV 98 (manual).
Apparently a 95-98 1.6 vitara Transfer will fit in.
Another solution I have heard is putting a 2000-2004 GV transfer in .
If anyone has done any of this or had the problem fixed , Info would be great. Thanks guys

[GeckoXL7]

I read it was the front Diff that made it pop out under load due to the ring and pinion gear slipping due to to much slack. There is also another problem mentiond somewhere on here about syncro's in the transfer case and a updated part number 29221-85F52

I have just gone through the experience of changing a transfer case and transmission as mine kept popping out of low. I was shocked at how many variants there was, may look all the same but when it comes to matching things up ,things sometimes just dont fit. Wreckers do not like selling a transfer case and transmission separately for this reason.

Eg there are 2 transmissions for earlier models than changed again in late 03 this is the case for a V6 Model. there is still two variants for the 2L, For me it went from a cheapish 480 fix to fit a new transfer to a almost $2000fix with all the mucking around and needing to pay extra for a transmission then new clutch etc etc etc. But 100% worth it with the pain in the ass it popping out all the time. For me it looked like it was a GV transmision with most likely the syncro issue prob same for you.

I would suggest talking to suzuki a good dealer would ask for your vin number and look it up and say yes its the syncro in the transfer or issue with the front diff. Then either get that part and fix it or work out through a wrecker what later model with out that issue would match up. New Model wreckers dealt with me, might be worth giving them a call, there cheap, honest and go out there way to help 2 hour drive though for you.

From Suzuki

Condition

Some customers may comment on a harsh clunk or popping noise coming from the front axle. This condition is most apparent while driving in 4WD at low speeds on loose traction surfaces such as gravel or snow and turning right or left.

Cause

Inside the front differential case, the teeth of the free wheel axle hub may jump a tooth resulting in the noise.

Correction

A modification was made to the design of the front differential case, which should reduce the likelihood of the free wheel hub teeth from jumping.

Replace the front axle differential case, actuator and side bearings using the service procedure and part numbers as shown.

Important: With the new design differential case, the teeth may still jump under extreme torque load conditions, such as making tight turn maneuvers in 4WD on hard dry surfaces resulting in a similar noise. This noise is now considered to be a normal vehicle operating characteristic. Driving on high traction surfaces in 4WD is not necessary and contributes to excessive torque load on the front axle. Customers should be advised to shift into 2WD when driving on such surfaces.

[GeckoXL7]

Auszooker thread on the prob http://auszookers.com/forum/viewtopic.p ... t=transfer