[Merk]

Just got my 6.5's in the mail and began trying to put them in. I got the case out fine but i cant make any of the flange nuts budge. The main reason being that each flange spins freely so i cant apply any force. I dont have access to a rattle gun so a torque wrench is my only option. I've tried clamping down the case and heaps of other ways to stop the flanges from rotating but i cant get the bolts to move. Is there something im missing that i need to remove before the flange nut, or do i need to get a rattle gun?
Thanks for any help

[fourby]

want33's, this one is for you ---->

[stuzuki]

i got mine off using a rattle gun.
if you cant get one just go to the nearest mechanics shop and ask him to do it.
will take him 5 mins.

[93zook]

DO NOT USE A TORQUE WRENCH TO UNDO THINGS!!!!!!

i used a monky wrench to hold it still against a bench and then a 3/4drive ratchet with a bit of pipe for a biot extra.

[steak_knife]

With the stick out you should be able to select 2 gear's, locking the transfer up, thay will be FT (fucking tight) tho, when looking at the nut you will see a lil bit that has been taped into a grove in the shaft, this is a locking tab & you need to tap it back up if you don't have a rattle gun!!!!!!

Hope that help's

[Ben_Sierra]

How do you select these gears, Steknig? I'm having similar issues...

[steak_knife]

stick out, look down hole, you will see 2 shaft's with cut out's in em, push one forward (think it's the right on) & BINGO!! locked into 2 gear's..

same thing can happen when the stick bush is flogged out, go to select high & it leave's in in low as well.

[v.w.dave]

Merk wrote:

Just got my 6.5's in the mail and began trying to put them in. I got the case out fine but i cant make any of the flange nuts budge. The main reason being that each flange spins freely so i cant apply any force. I dont have access to a rattle gun so a torque wrench is my only option. I've tried clamping down the case and heaps of other ways to stop the flanges from rotating but i cant get the bolts to move. Is there something im missing that i need to remove before the flange nut, or do i need to get a rattle gun?
Thanks for any help

hey mate call me if you havent already got it apart.
Pm sent

[want33s]

You can't select two gears at once as one stick is HIGH/LOW and the other is 2/4WD.... If you could select two gears it would only lock up the case.. That wouldn't help undo the nuts cause the whole case would roll across the bench.

I use a 3ft long (900mm) piece of 2" angle(50mm) with two holes drilled in it and bolt it to the flange.
I then use a socket (27mm I think) and a breaker bar with a piece of pipe over it to turn the nut.
Make sure you drive a small screwdriver into the locking tang in the nut first, it only helps a bit but it helps.


I can post pics if needed but not till tomorrow.

[steak_knife]

Can. Seen it , done it, race you in 2wd.

[89_tintop]

steknig wrote:

Can. Seen it , done it, race you in 2wd.

is that the new thing to do

[want33s]

steknig wrote:

Can. Seen it , done it, race you in 2wd.

You name the time I'll name "THAT HILL".. :rofl:

[royce]

nope cant, at best youll get high 4 or low 2

plus there is a detent in the way

its not a gearbox

[Merk]

Well i finally got them off using want33"s idea, and needed to use a bearing puller to get the actual flanges off. I bent the bolt from the bearing puller trying to get the input flange off though so thats still stuck on. I've tried using a hammer to get it off but im having no luck. Anyone got any other ideas for getting the flange off or do i need to go buy another bearing puller?

[want33s]

I assume you have already applied a liberal dose of CRC/WD40 etc.....


Buy another puller.
While there is good tension on the puller tap the flange sideways with a brass mallet this will loosen any rust that may be holding it....
Heat is a LAST RESORT and should be avoided if possible.

[v.w.dave]

The next question will be how dose he get out the speedo.

[ajsr]

http://www.trail-gear.com/pdf/suzuk-tcase.pdf
go for your life

[v.w.dave]

ajsr wrote:

http//www.trail-gear.com/pdf/suzuk-tcase.pdf
go for your life

Thats a really good how to.... ROYCE good for the how to section...

[Merk]

Well i bought a new puller and got the flange off all sweet. Now i've started pulling apart the gears and realised i dont have a press to get the bearings off. Can i just use a hammer and socket or will this damage the bearings? What have others used?

Also while trying to get the countershaft out, a small plastic thing fell out of the centre casing. I think it may have fallen out of the little notch that can be seen the the top left hand corner of this pic http://www.trail-gear.com/tech/zuk65gea ... 62-600.jpg (at the shaft hole) Anyone have any idea what this is and where it goes?

Sorry for all the noob questions, just dont want to break anything
Thanks heaps

[birko]

Just finished mine on the w/end. Did it without a press but i would be a lot easier with one. To get some bearings off i used a 3 arm puller, To get the worm drive i think off one of the shafts i improvised a press by using my twin wheel carrier on my courier, hi lift jacked it up then place the shaft in between to bits of steel the released the jack, dodgy but it worked. Use your old bearings/ diff size pipe to hammer on/press your new bearings etc.

I also had that bit of plastic but didnt know what it was, I put it back together without it.

[Rusho]

v.w.dave wrote:

ajsr wrote:

http//www.trail-gear.com/pdf/suzuk-tcase.pdf
go for your life

Thats a really good how to.... ROYCE good for the how to section...

x2 I would even have a go at it....its almost idiot proof

[jimbo_jones]

Rusho81 wrote:

v.w.dave wrote:

ajsr wrote:

http//www.trail-gear.com/pdf/suzuk-tcase.pdf
go for your life

Thats a really good how to.... ROYCE good for the how to section...

x2 I would even have a go at it....its almost idiot proof

Ive done 2 t box's using this trail gear manual with no probs

[steak_knife]

want33s wrote:

steknig wrote:

Can. Seen it , done it, race you in 2wd.

You name the time I'll name "THAT HILL".. :rofl:

That hurt's Jas