8.1 Transfer Case Gear Set???

[ScottieJ]

Just out of curiosity is that 0.001" (0.0254mm) oversized in comparison to a set of standard gears? Obviously you are a million times more experienced than me when it comes to machining but I'm wondering if that would still be within factory tolerances for suzuki?

I'm quite surprised the larger gear has that blemish and has been blasted. Rob's gears have always been regarded as the best you can get to it's not the sort of thing I would expect to see

[TanZuk]

Just out of curiosity is that 0.001" (0.0254mm) oversized in comparison to a set of standard gears? Obviously you are a million times more experienced than me when it comes to machining but I'm wondering if that would still be within factory tolerances for suzuki?

I'm quite surprised the larger gear has that blemish and has been blasted. Rob's gears have always been regarded as the best you can get to it's no the sort of thing I would expect to see

To try and answer your question about the oversize condition. The conversion to metric that you have is correct.

I have a set of stock gears that I had pulled from a case that I had change gears out on. I set the dial bore gauge to the origanal stock bore which had atleast 125 thousand miles on it. With this amount of miles would probably make the stock bore on the larger size of maxium tolerence anyway.

The new gear was .0245mm or .001 bigger then this size. There are cage bearings that locate the gear on a shaft. That seems to be alot of slop on that type of bearing with the added stress of the reduction gears.

I'm just tring to get through this purchase with out having any more headaches. I sure hope Rob doesn't try to pull that nonsence that he pulled on chris410 with me.

Scott, I would totally be embassed if something like those pics came out of my shop and I tried to get away with selling them.

I will give Rob a chance on taking care of the problem with the polite email I sent him along with the pics of the gears that he sent me.

Unfortunately to be continued.

I will say that I feel bad for the people that do buy parts and have no way of checking if the parts are good or the knowledge to make a determination. Just because it is new doesn't mean the part has been made correctly. Remember places that make parts very seldom throw anything away unless it can't be used at all.

[ScottieJ]

Cheers for the explanation, hope it didn't offend, I was just curious to see what you had compared the measurements from.

I've never heard of an of his gear sets failing, even after years of abuse by someone I know. I've also known a few cases with his gears that have been around a few owners with no issues, however that said we don't tend to run tyres your size very much in the UK so there would be less strain on them.

Either way I hope the issue get resolved, I feel bad for recommending his gears now, I really wouldn't expect them to not be up to standard after the reputation his gears have over here.

[TanZuk]

Scott really no need for you to feel that way. It is like telling some one the food has always been good at a certain place. Things happen.

I have bought so many parts now and there alsways seems to be something with them. I could write a book on some of the really bad ones that took 6 months to take care of. One was Isky Cam (don't like to be a name dropper) they by far were the worst ones yet.

It will all work out in the end. It always does it is just more time wasted on fixing something that shouldn't have been a problem to begin with.

[TanZuk]

Scott, since it is just you and I talking about this maybe we should just PM the rest if your interested.

Terry

[TanZuk]

Update on the gears and proceedure on how to clearence the housings for the gears to fit.


Wanted to show the TCG after a couple of weeks of soaking and some elbow grease to try and get rid of the rust that was on the gears when I received them.


With Rust pics








Cleaned up gears





Chose to go this route rather then deal with Robs attitude at RS Manufacturing. If I didn’t think that I needed these specific gears they would have been sent back.

[TanZuk]

Purchased the UK 6.1 Transfer Case Gears

Thought I would share some info on the 6.1 Transfer Case gears with the 24% high gear reduction since there doesn’t seem to be any reference info to be found.

Wanted to purchase the 8.1 TCG with the 24% High Gear Reduction unfortunately they were not available for 2 years. Ended up with the 6.1 instead and had the same high gear reduction as the 8.1 TCG.


The not so good:

These particular gear sets are only offered in the UK and shipping is pricey. There is very little info provided from the manufacturer on the gears and there are no installation instructions provided to show the clearance procedure. You will need to purchase a complete rebuild kit from one of the venders because you only get the gear set, gaskets and some squashed seals. These gears will probably show up with surface rust on them because of environmental conditions in the UK.


Clearance the housings::

The 6.1 Countershaft Gear is a bit larger then the Trail Gear 6.5 Countershaft Gear. There is a need to clearance the case for the gear to fit.

The Mill was the tool of choice used for these reasons:
Maintaining a consistent radius to a determined depth.
Large amount of material being removed.
Thin walls after machining.

( There was about 3/16” removed from the side wall and about a ½” depth. This gave about a .050 clearance all the way around on the machined surfaces.)

Here are the housings being machined for the Gear.

Short Housing Pics.

[TanZuk]

Large Housing Pics








The break through hole will be taken care of with a set screw with thread sealer theaded in from the opposite side. Yes if your thinking that is very close. Took it to the limit to not weaken the housing or cause an outer break through.

Going to be using a Zor Snatch to strengthen the unit and will help with the extra material that has been removed from the housings.


As you can see there were several obsticles in the purchase and installation of these gears. Now there is atleast some first hand info on these gears that can be shared.