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ZUKIWORLD Discussion Forum => Suzuki 4x4 Forum => Topic started by: Shrock on August 10, 2005, 08:24:20 AM

Title: Help with tcase gears
Post by: Shrock on August 10, 2005, 08:24:20 AM
Installing 4:1 gears in the kick case.  We have an xtra frigging ball that I dont know WTF it is.  Can someone send/fax/email the Factory schematic of the tcase?  The Haynes manual isnt helping.

There are five large balls I've seen.  Not counting the little BB sized one under the trWe know where four go.  There are two under the two phillips screws on top (#1 & #2).  One under the 4wd sensor (#4) one in (#3) with a machined pin....and one more mystery ball.  The mystery ball is the same size as the smaller ones under the two phillips screws. 

We were dropping the case on the table to get the low output gear off per the TT instructions when the ball fell out from......who knows where......   
Title: Re: Help with tcase gears
Post by: ebewley on August 10, 2005, 08:39:44 AM
Quote from: Shrock on August 10, 2005, 08:24:20 AM
Installing 4:1 gears in the kick case.  We have an xtra frigging ball that I dont know WTF it is.  Can someone send/fax/email the Factory schematic of the tcase?  The Haynes manual isnt helping.

There are five large balls I've seen.  Not counting the little BB sized one under the trWe know where four go.  There are two under the two phillips screws on top (#1 & #2).  One under the 4wd sensor (#4) one in (#3) with a machined pin....and one more mystery ball.  The mystery ball is the same size as the smaller ones under the two phillips screws. 

We were dropping the case on the table to get the low output gear off per the TT instructions when the ball fell out from......who knows where......   


Hi Jim,

I don't know if you looked at this already or not but we do have an install article for Sidekick Calmini gears it would be pretty similar. It's in the Gear Guide section http://www.zukiworld.com/month_010103/feature_calminirockcrawler_sidekick.htm and it might help?

Where's Mikey? He'd know what it went to. 'cuz he knows dem t-cases like the back of his head, I mean hand. :)

-Eric
Title: Re: Help with tcase gears
Post by: Shrock on August 10, 2005, 09:29:03 AM
Eric,

I actually looked here first for a install writeup because you guys do such a great detailed job on them, but I couldnt find one.  I always seems to have a hard time finding the tech articles in the archives.  Thanks for the link. 

Unfortunately the mystery ball didnt show in the steps.  I'm beginning to wonder if someone had it apart previously and lost a ball in there so we have an extra one.
Title: Re: Help with tcase gears
Post by: Shrock on August 10, 2005, 11:02:37 AM
Brent to the rescue!  There is a ball that goes b/t #1 & #2.
Title: Re: Help with tcase gears
Post by: SnoFalls on October 08, 2007, 08:49:45 AM
thank gawd for search foo ...

I had the *exact* same thing that happened to shrock happen to me saturday doing my tcase ...

I figure if it's happened to 2 seperate people, it's worthy of bringing to the top so it doesn't disappear from the searchers.
Title: Re: Help with tcase gears
Post by: crikeymike on October 08, 2007, 02:48:06 PM
I found this post a few months back when i had the same problem, and it answered my question very quickly.
Title: Re: Help with tcase gears
Post by: LilRed on October 08, 2007, 03:10:57 PM
Us too. 
Title: Re: Help with tcase gears
Post by: SnoFalls on October 08, 2007, 03:19:13 PM
ok, who wants to bug brent ahout revising his instructions  ;D

they are so very good except for this "ow-crap now what" ...

Title: Re: Help with tcase gears
Post by: Drone637 on October 09, 2007, 09:01:09 AM
A little * at the bottom.  "If you have a left over ball, it probably goes here"   ;D