Friends,

I have a 1.3l mpfi Gypsy King (SJ413) in India. It already has 'Lockrite lockers' in the rear and now I am planning to get the "Trail Tough 4.16:1 t-case rockcrawler gearset" installed. I need advise:

 - Is the install a straight replacement of the stock t-case gears with this or does this involve some kind of grinding/welding etc?

- Does this install require some other parts to be modified for strengthening to handle the extra torque? Will the stock axles/drive shaft etc be able to handle the extra torque?

- Is it 'MANDATORY' to install a reinforced t-case mount if one is using an ultra low t-case gearset?

I ask all this because in India we don't get these parts and I am importing all these from USA. So want to be 100% sure of what I am getting into.

Cheers,

No grinding or welding is required for the 4:1 gearsets.  The current gearsets are billet, and simply replace the original gears. There are some how-to's online if you choose to do it yourself (I paid Trailtough to convert mine).  This might be a good opportunity to rebuild/overhaul the T-case, while you have it apart, even though it may not yet need it. 
 
Stock drivetrain should be fine for the 4:1 T-case. It is, in the end, a matter of terrain and driving style. If you stay with small tires, say 30" and under, you are less likely to increase stresses to the breaking point. 

Ultra-low T-case gearsets are 6:1 and 8:1 and are often used with much-larger-than-stock tires. This combination almost mandates something like TT's MightyKong, one of the most popular cradles.  I run a 4:1, stock T-case arms, a Detroit locker and 28" tires -- no problems for me so far.  But I will reinforce the stock T-case mounting arms someday soon, just because I can.  I'm sure others will have opinions as well.
 

.... 
Stock drivetrain should be fine for the 4:1 T-case. It is, in the end, a matter of terrain and driving style. If you stay with small tires, say 30" and under, you are less likely to increase stresses to the breaking point.  ....

Thanks Merlin. That helps. I plan on running 31x10.5x15 tyres. So I am assuming that all stock drive train should hold good for that tyres also.

And yes, while I am it, I will get the t-case overhauled -- anyway it will be opened :-).

Cheers,

Friends, I have one more doubt about the low t-case gearset. It mentions that it gives 84% reduction in Low and 12% reduction in High.

Does this mean that it lower the high range 2WD and 4WD as well (and at the same 12% reduction)?

I can understand the 84% reduction in 4WD-L

Cheers,

Yes, it drops the high range as well.  This will bring your gearing back to stock for your 31" tires, giving you your power back when driving around town.

If you have been thinking about running a twin stick in your sami, i would think about pulling the shift detent ball out.  I totally forgot to take mine out when i had the case split, and i don't feel like taking it apart again.

Amilla

Friends,

Got the 4.16 t-case gear's installed and have also put in Maxxis Trepador Mud Terrain tyres (235/75/15).

The detailed install report is mentioned here with pictures

http://www.team-bhp.com/forum/4x4-off-roading/47922-gypsy-steroids-rockcrawler-4-16-1-t-case-gearset.html

http://www.team-bhp.com/forum/4x4-off-roading/51700-gypsy-steroids-maxxis-trepador-m8060-mud-terrain-tyres.html

We went to do some off-roading recently and here are some of the pictures/report:

http://www.team-bhp.com/forum/4x4-off-roading/52551-munnar-otr-general-reports.html

This is how my Gypsy looks now.

Nice looking Suzuki!

That is some beautiful land!!!!!!

If you didn't replace or strengthen the mounts do it now. They will bend even with little tires. I bent 2 sets in my little samurai.

Great to hear from you again.  I like your note on the other forum. 

The MGE was a joke. A serious joke. Infact a CLASS action suit should be filed against those folks for insulting the jeepers if they call that highway/tarmac route an OTR trail.

That is a lot of old school iron. 

Thanks for the comments folks. With the Lockers + 4.16 t-case + Good tyres, the Suzuki is ready to take on most terrains that we have here in India.

I have replaced the t-case mounts and very soon will be strengthening the t-case arms also.

Cheers,