Suzuki Club UK

so I'm currently in the process of rebuilding my tbox, and have encounetered a shim that I don't know where it is supposed to live. I did some investigation, and had a look at where the flanges fit on the tbox. we can see the shaft, and the oil seal, and a gap. There is a protrusion on the flanges that fits in this gap, and seals it off. I then had a look at the handbrake drum and backplate. I found that the drum is too small for the backplate, and the protrusion/thingy doesn't extend beyond the backplate, and therefore doesn't fill up the gap between the shaft and oilseal. so then I found I can fit the shim in this gap, to fill it up, like it should be. I am thinking someone tried to match the wrong drum to the tbox. .

so what are you people's experience regarding these issues? maybe some photo's of the drum and backplate like it should would be greatly apreciated

The other issue I have is that I could not quite get the case to close properly, but could pull it close with some bolts. however, this caused the tbox to turn rather tightly, is this is right? and if now, what is wrong?

anyone got some pics of a standart handbrake drum and backplate?

I've got this backplate pic if its any good for you.

yeah, that looks the same as mine. the other thing I am interested in is a pic of the drum itself, see how far the centre bit extends beyond the backplate.

ps, will try to get some pics up for you ladaman regarding the handbrake setup

Did you use a gasket on the case or just silicon sealant ??

Hope this diagram helps...........

looking at that diagram, is that green thing supposed to be some sort of shim? might be my mystery shim.

haven't used any gasket yet, just closed the case up to see if it was all working, still got to put some gasket sealant in, it's what was used when i took it apart, so should be alright now, unless I need a proper gasket to free the box up a little now

Yes the green bit is the shim/spacer..

Here's a link to the workshop manual http://www.4x4.in.th/manual_sj413/chapter14.pdf

Page 14 gives the case clearances.

I've never pulled one apart so "I Dunno"

thanks darell, that's exactly what I needed. to measure the clearances, you need to measure the depth of the bearing seats in the cases. what's the best to do this? I used my vernier caliper, and laid a steel ruler over the face of the case, and lined the vernier up with it, but it's not very accurate. what the best way to do this?

also, does anyone know if there are different thickness thrust washers available for the counter gear?