Help - Gearbox noises????

[Darrell]

I'm going to say go with number 2 . I've only ever taken the rear output flange off and that was dam tight, but heat and brute force should do the job. Your going to have to take the flanges off your existing box to investigate what has failed on that anyway.

If you do repair it yourself your be needing this http://www.4x4.in.th/manual_sj413/chapter14.pdf" onclick="window.open(this.href);return false;

Hope you can sort the bugger

[ScottieJ]

the flanges will swap over

Another option is to drill another set of holes at 45 degrees to the existing holes to match your props, its a common solution that people do when fitting Toyota propshafts or axles.

[timpaton]

OK, how do i get the flanges off, I'm guessing a special tool? were can i get one? or is it a make one job?

[dan_2k_uk]

A big bar with a plate on the end with holes drilled to match the flanges and a big hole through the middle to access the nut.

Think Darrell has photos of his so expect them soon. They are on a thread somewhere about the drum handbrake so I will have a look now.

Dan

[dan_2k_uk]

Here you go. Obviously the holes might need adjusting for your flanges.

http://www.suzukiclubuk.co.uk/phpBB3/ph ... 3&start=10" onclick="window.open(this.href);return false;

Dan

[timpaton]

Sorted, new tbox from ebay, problem has gone away

[Rjmaas512]

Did the same thing with mine as well, no horrible noises.

New problem: Gear selector bolt is dead, and the thread is well non existing so making a new one sometime next week when I have access to a lathe and tapping a larger thread.

Darrell, where did you get that oil seal from? I need to replace mine at some point.

Cheers,

Rob

[Darrell]

The oil seal is a little special as it has a protruding lip/seal which makes it a Suzuki part only. However the seal size is 32/42/10XLTJ and a standard 32/42/8 or 32/42/7 double lip r23 from any bearing dealer should work OK although the suzuki one is brown and probably made from vitron which is more heat resistant.