Suzuki Club UK

Jumpinjacks wrote: I will check the gaiter later, also I am wondering if it could be the rubber seal underneath the lever

Do you mean the shifter sheet?



if these are worn they can cause the problem you are having.

If you made sure all 3 detent balls were fitted as they should be and that the front output was shimmed then i'm sure that it will be fine, when you say the front prop has play though where exactly does it have play? do you mean that the front output has play? if so it could need a new output bearing and that could cause the tbox to pop out?

And yes that is the bearing you remove for the 2wd lo mod

Yes thats the bit I mean.
The prop has play in the joint. There is no play when trying to wiggle the output flange.

Try swapping the shifter sheet for the old 413 one then, that might solve the problem.

Have you tried putting it in 4 low, then taking the stick out?

I had to do this on a previous sj when the stick was bent

I have chnaged the shifter sheet for the 413 one even though the 410 looked fine tbh. I also noticed the crossmember bolts were very loose, which tbh was probably the reason it was happening. So I loctited the bolts and made them nice and tight. The gaiter was on the right way.
Hopefully this should solve any problems, cant test it properly until Sunday. Will let you all know if its ok now.

Well the problem is that the bolts that connect the crossmember to the transfer box keep shaking loose.
I took each bolt out and put some loctite on one by one with the t box in place, and done them up as much as I can in the space.
And still the problem persists. They have come loose again. I am wondering whether it is the new land rover engine mounts I have used which cause the transfer box to not move at all, so maybe the force is being put into the bolts instead. Do you guys think I should use standard mounts again instead, and take the tbox out and fully tighten the bolts?

Sounds to me like that could be causing it, you could either go back to stock bushes or build a guard/brace for it, that will help reduce any flex in the case and also protect it better, I have seen sj tboxes literally break in half when H/D mounts have been used

If you can't weld then Rockwatt on here makes nice ones for a good price, he's in the traders section.

That guard looks perfect.
I think I will go back to stock mounts and see if that helps.

i made the hole in the floor around the tbox stick bigger. used gaitor out of a old transit. happy days.

Russ24 wrote:i made the hole in the floor around the tbox stick bigger. used gaitor out of a old transit. happy days.

Thats not the problem as the bolts would still shake loose and eventually come out.