Leaky Transfer Box

[Jordi]

I did read somewhere the easiest "tool" to remove it is an ikea style z shaped allen key. You can sometimes get them hooked inside and get a pair of pliers onto it to pull them out.

[NylonAdmiral]

Thanks for the tip Jordi, I'll have to see if I have one knocking about. Failing that I'll see if I can perhaps make something!

[Jordi]

Knew i'd read it somewhere.

http://www.suzukiclubuk.co.uk/diy/16-tr ... ocklobster

Who'd have guessed it would have been on this website.

[NylonAdmiral]

Who'd have guessed it would have been on this website.

Ha ha, of course it was!

Thanks Jordi.

[dan_2k_uk]

I've also seen people cut the cable off so you just have the part that inserts into the box and then put a blob of weld on it to seal it up then just leave that fitted as it has a seal on it anyway.

Would do the trick if you still have an old cable lying around.

Presume you just pull the little bit of cable out of the sheath first to avoid welding it stopped so to speak.

[NylonAdmiral]

Thanks Dan.

I actually found that the sender just pulled out reasonably easily.

I'm going to get another o-ring then call my local Suzuki place and see how much a seal is. If they say they can't get one or it'll take ages then I think I'm just going to turn up a blanking plug on the lathe and fit that in instead.

[NylonAdmiral]

In case anyone else has the same problem, I thought I'd add the following info.

The o-ring you need is just an ordinary 19mm ID o-ring. Alternatively if you want one from Suzuki, the part number is 09280-19001 and they're about 60p.

Also, most of the exploded parts diagrams have two different part numbers for the oil seal.

One is 29973-80050 and the other is 09282-08001, although they look identical on the drawings. I called Suzuki and they had no idea what the difference was.

They were only a couple of quid each so I bought both so I could post the differences here and keep whichever is the correct one.

From looking at them both, either part number will work. It looks like one is just an upissue of the other.

I dimensioned them both with a vernier and they have exactly the same physical dimensions.

If you have one that is all rubber, then the part number is 29973-80050. If you have one that has a metal outer edge to it (a bit like the rear axle oil seals) then the part number is 09282-08001.

[Darrell]

I did have the part numbers for the oil seal but didn't post them as I had no idea what the differences are, so thanks for the info.
My searching also says the seal is 8x16x5mm

The O-ring came back as 1.9mm diameter and 18.8mm ID
But I expect a 2mm X 19mm would fit fine as that probably what you have.



I'll have to do a diagram

[NylonAdmiral]

Thanks Darrel, I wrote the dimensions down but left them in the garage, I'll post them tomorrow but yours sound about right.

I actually got the o-ring from Suzuki so I'll confirm the dimensions for that too.

[Darrell]

Hope this is correct...