[swifty_ano]

Ok all....I have searched and found numerous threads about dual cases being a Good idea and a Bad idea.
Keep in mind, this thread is only to make myself more knowledgable on this subject. I would like to do this mod....but the chances are great.

I have read numerous threads about fitting a sierra/hilux transfer case behind a vitara transfer case.
A few post have mentioned pre fabbed kits available but the business has seem to be non existant now (OTT Industries)


I have read post about people who have made their own kits. The amount of work gone into these kits seems excessive for the actual gains.
http://bbs.zuwharrie.com/content/topic,46349.0.html

However, I can't find any recent threads of installs with all the new products available to buy.
I have been thinking about this long and hard and I can't see why you can't just:
*Cut the front output from the vitara transfer case and seal it up
* Install a slip yoke elimnator in the vitara rear out put ---- like this one http://www.lowrangeoffroad.com/index.php/suzuki/sidekick-tracker-x90/drivetrain/sidekick-tracker-slip-yoke-eliminator.html
* Run a stock intermediatet shaft from slip yoke eliminator to sierra transfer case (shorten the shaft to decrease size taken up?)
*install sierra transfer case in position. welding custom mounts on chassis and run something like this -- http://www.lowrangeoffroad.com/index.php/suzuki/samurai/transfer-case/suzuki-samurai-eos-extreme-duty-transfer-case-cradle.html
* install sierra drive shafts front and rear (custom length)


How would this work?

I have read if you shorten the shaft between the two transfer cases, the sierra gear leaver should fit through the stock hole in the floor.



OR ALTERNATIVELY

If I install an Auto box into my vitara. How would an adapter like this (http://www.lowrangeoffroad.com/index.ph ... apter.html) Help me?
My thoughts are somehow it allows me to intstall a sierra case...

[Fatzook]

What are you trying to achieve?

A sierra case is pointless in a vitara, as they are offset drive. Not to mention that your SWB vitara doesn't really have room for a second case and managable rear driveshaft length.

[swifty_ano]

Fatzook wrote:

What are you trying to achieve?

A sierra case is pointless in a vitara, as they are offset drive. Not to mention that your SWB vitara doesn't really have room for a second case and managable rear driveshaft length.

Are hilux transfer cases off set as well?
Would the only advantage be more gear options. I.e USable high range on the beach?

[DarkHorse]

1) keep the stock Vit front output and turn it into a PTO

2) ideally you wouldn't need a jack shaft from a slip-yoke eliminator to the transfer input, just bolt flange to flange. Would save some length, but depends if you can mount it in a suitable posi.

3) How would a second transfer case end up anywhere near the stock hole in the tunnel? It'd be under the handbrake assembly wouldn't it?

4) Rear drive shaft in a SWB would be about 6" long and run on a horrible angle

5) Hilux transfer outputs are similar to ours:

The length of the whole bell/gearbox/transfer assemblies are also actually quite similar (W or G series, not Rs) and they are available in a forward shift transfer like the one above.
They don't have a flange input though, so it would need a bit of stuffing around to adapt in.

[swifty_ano]

So in theory if one installs a 4 speed auto. They can install a Sierra transfer case (with reduction gears) in the same location as a vitara case would sit with the use of an adapter?

[Fatzook]

swifty_ano wrote:

So in theory if one installs a 4 speed auto. They can install a Sierra transfer case (with reduction gears) in the same location as a vitara case would sit with the use of an adapter?

You will still have driveshaft alignment issues, and you will get a 20% reduction in highrange gearing. Thats with stock sierra transfer gears. 6.5's would be 35-40% lower in high than stock vitara. You'll need 38" tyres to drive on the highway.

[Teracis]

Just spend the money on gears for your vitara transfer case dude, one of the lads we wheel with has and loves it.
I've looked into it a fair bit on here (for putting in a sierra) and it is just not practical when you have off the shelf options for such a low cost.

Ask a few of the old hats on here who have done it, especially joeblow, there is major work involved (talking about sierra's here) and they only used to do it before the reduction gears became readily available. If it's harder in a vitara unless you're looking for a specifically hard project you're already pushing shit uphill.

I'd really like to say go for it man but if I got talked out of it then you should be talked out of it too because it's more work and money than it's worth!

[swifty_ano]

Thanks for all the info guys. It's been a real big help.

As I stated in my first post, this is more to find out if my thoughts were possible. I really don't intend on doing this, I just had a thought and would like to expand my knowledge on how one would implement this thought.
I'd really like to work out if what I thought would work, actually work? Practical or not, it would be good to know for future reference.

[Teracis]

swifty_ano wrote:

Thanks for all the info guys. It's been a real big help.

As I stated in my first post, this is more to find out if my thoughts were possible. I really don't intend on doing this, I just had a thought and would like to expand my knowledge on how one would implement this thought.
I'd really like to work out if what I thought would work, actually work? Practical or not, it would be good to know for future reference.

I did the same thing a while back, I have since learned that there's quite a bit of space between the vit gearbox and transfer and am still wondering if something could be done there, without having taken a transfer off a vit box myself I can't know if there's other stuff that fills the hole but it just seems like wasted space!

[DarkHorse]

Fatzook wrote:

... a 20% reduction in highrange gearing. Thats with stock sierra transfer gears.

Sounds appealing actually

[swifty_ano]

Teracis wrote:

swifty_ano wrote:

Thanks for all the info guys. It's been a real big help.

As I stated in my first post, this is more to find out if my thoughts were possible. I really don't intend on doing this, I just had a thought and would like to expand my knowledge on how one would implement this thought.
I'd really like to work out if what I thought would work, actually work? Practical or not, it would be good to know for future reference.

I did the same thing a while back, I have since learned that there's quite a bit of space between the vit gearbox and transfer and am still wondering if something could be done there, without having taken a transfer off a vit box myself I can't know if there's other stuff that fills the hole but it just seems like wasted space!

I do believe it is only occupied by an input shaft and the front output gears. In the like I posted, it had pictures of the front of the front of a t/case.

DarkHorse wrote:

Fatzook wrote:

... a 20% reduction in highrange gearing. Thats with stock sierra transfer gears.

Sounds appealing actually

It kind of does....if only the driveline vibrations weren't an issue. I have read a double carden joints help a lot?

[DarkHorse]

This is a Vit transfer exploded:

Front section is on the left - there's not much depth there. From memory the output shaft of the gearbox doesn't have a great deal of air around it either:

[Teracis]

I'll have to check but that's the part I'm talking about, the bit in your bottom picture, with that removed there's a huge (150mm?) air gap between that plate and the next part of the gearbox and there's nothing there. I'll go looking and find a link to a pic now if I can or take one tomorrow.

EDIT: My bad, the pic you have at the bottom looks like it has that all removed, I'll have to find the pic still but the one I'm talking about probably has part of the transfer still bolted onto the gearbox!

[DarkHorse]

OK... this is a gearbox and transfer installed:

The transfer bolts on at the join above the uni. The next row of bolts (heads facing forward) is where the box joins the bellhousing, there's no other place to split them...

[Teracis]

Found one!

This is one from Joeblow showing what I think I was on about, I'd have to check my gearbox when I get to dads but afaik it currently has the back plate of the transfer missing so I was right about the huge airgap only it's because I'm looking at the transfer with the guts missing

viewtopic.php?p=563098#p563098

[DarkHorse]

Ah yes, I have seen that photo. Looks roomier than mine did, but I wasn't looking that hard. That shot might be a bit deceptive...

The second pic I posted still has the first section of the transfer by the looks of it, so you were right on that.

I still don't think it's a realistic option for shortening, as you'd have to cut and shut the casing, and shorten the output shaft

[Teracis]

Ok so I took these last night, clearly still has the front of the transfer on there with the guts missing, my bad

[DarkHorse]

Either way, it'd be a lot of work to shorten it!

[Teracis]

I think I've got it in my head now, you were talking about that part being the bellhousing between the gearbox and the transfer! I'm just a stooge and thought that they would have used that space for something useful (or did they?) instead of wasting it.