DIY Suzuki Samurai SJ413 Transfer Case Full Rebuild with

[@Rishank]

Great video, thanks for sharing this. I need help as im a noob at this. I'm from India and i have a sj410 converted to sj413w which is the wide track with g16bb engine which is the 1.6l. I have the 1.0l transfer case which mechanics here say outputs more torque compared to the ratio of 1.3l transfer case but the vehicle can't go above 100kmph. Currently I'm facing an issue where the low gear slips under load and I plan to rebuild it. I'm not able to understand what this 4.16 gear ratio is and how it helps. I checked out Calmini website and they talk about 12% reduction in high and 83% reduction in low. What reduction is this can you please explain. I want a setup that helps in offroading as well as high speeds. I also wamt it to be fuel efficient. Hope i havent confused you and any reply is much appreciated. I'm running 30" MT tyres.

[@whiteknightandshorty]

Hi, thanks for your comment. I'm not sure without comparing the two transfer cases you have there in India. We don't get all the neat stuff the rest of the world has! To explain the basic principle, when you lift and increase tire size, you change the final drive ratio, and often those engines are anemic to begin with, so you need to lower the gear ratio back to around stock for the engine's best performance. You can do this by replacing both differential gears, or for what many of the guys do, you can replace the transfer case gear set that will reduce the high and the low, which will bring you back down to a better gearing, and slow your low crawl speeds, which is a "win-win" in most situations, and much easier than setting up two differential gear sets, while not affecting low range ratio. You have a few choices when ordering a t-case gear kit. You should calculate the ratio kit by percentage to get you back to your original gearing. I can go into this a little more, so let me know if you need me to do so. It sounds like the 1.3 t-case you mentioned must have a lower ratio high, which is why it limits the speed. There's kind of a power/speed balance you have to find. This brings me to the efficiency range... There is a decrease of efficiency when you increase rolling weight/friction/wind resistance etc by increasing tire height. My suggestion is to find the lightest weight tires you can with the tread pattern you're looking for. Heavy mud tires slow you down and cause more wear and tear on everything, but if they serve your purpose, great! All terrain are better for street and more mild manners, but lack bite and mud clearing etc. You will reduce efficiency but gain off-road capabilities. I hope this helps. Let me know anything specific and I'll try and help. Thanks and good luck!

[@katanaasik]

👍👍👍

[@whiteknightandshorty]

Thank you!

[@sailorsanjoy]

I get a high pitched whistling noise at speeds exceeding 60 km/hr . Could it be because of the 4.16 reduction gears I installed in my zuki?

[@whiteknightandshorty]

I think yes. Every set I've installed has needed a bit of break-in time, where the whining noise will calm down over time. It's not abnormal to have a little audible whining, but nothing very loud, and nothing you can feel. Only slightly, but noticeable. Drive it!

[@minangindon9473]

Bos aku kata samurai long sasis tc rusak gigi barbel ada nggak suku cadangnya.terimasih.

[@whiteknightandshorty]

I'm sorry for the translation difficulty, but I think, you're welcome? Good luck! Thanks for the note!

[@firmansudarwan5556]

Jos gandos

[@hebdomatical]

I don't understand the stainless-steel studs. Stainless is usually not as strong as regular steel.

[@whiteknightandshorty]

I like to use them because I've found they work well for me. They stave off rust and allow me to switch transfer cases from a lower range to a higher range case (depending on usage) quickly, without wearing out or weakening the threads cut into the much softer case.

[@diymechanic5503]

Can't see anything you are doing. Bummer.

[@whiteknightandshorty]

Sorry for not being too clear. Videos are hard to make! If you have any questions, I'll try and answer them.