[Davidmacca]

I am half way through swapping transfer case over in vitara without pulling the gearbox out does anyone know the steps to do this as I have come to a stop trying to undo the bolt between casing and gear linkage

[christover1]

Only done it on my Auto, with a 50mm body lift, so can't help specifically.
Reaching the top few bolts on mine meant buying a 1/4" drive socket set

[shandy92]

mate do you mean you cant get the 4 bolts that hold the gearbox linkage housing? Once you have those bolts out tap it from the underside and it should pop off. This has to come off to get to the bolt in the cavity. If you can take a photo of what you mean it would help. Also have a search in darkhorses built for more pics.

[Davidmacca]

shandy92 wrote:

mate do you mean you cant get the 4 bolts that hold the gearbox linkage housing? Once you have those bolts out tap it from the underside and it should pop off. This has to come off to get to the bolt in the cavity. If you can take a photo of what you mean it would help. Also have a search in darkhorses built for more pics.

Yes that's why I mean but I can't undo the 4 bolts, do I just keep trying different tools to get in their, was just seeing if their was a different way
Thanks

[shandy92]

oh ok, well i just used a 3/8 ratchet and socket. Shouldnt be that tight. I found breaking the silicon seal harder.

[Davidmacca]

shandy92 wrote:

oh ok, well i just used a 3/8 ratchet and socket. Shouldnt be that tight. I found breaking the silicon seal harder.

Ok cheers, should I pull the stick out first to make it easier to get to the bolts or leave it as one unit

[got_bar_work]

Put it in neutral and take it out
Dont drop the bush on the end of the stick
Check the seat bush as well while its out
And the slots down the ball
They shoud be nice and tight on the bolts they slide on in the side of the case

[DarkHorse]

Yes, stick needs to come out.

If you're having trouble getting a tool to the front four bolts you can get a jack or ratchet strap under the gearbox (in front of the bolts that you're undoing to get the transfer out) to support it, undo all the mounting bolts and pull the crossmember out, then lower the gearbox a couple of inches to give you some space.

Keep an eye on the clearance between engine bits and firewall as you lower it so you don't munt anything.

They're still a bitch, but at least you can get a hand in.

[Davidmacca]

Thanks for that I have swapped it over but now it is troubling me Getting the linkage housing back on and good ideas ?