User guide

ManualsBrandsAdvance Adapters ManualsCar48-6400

ADVANCE ADAPTERS INC. P/N: SUZUKI

P.O. Box 247, 4320 Aerotech Center Way New Item: (09/09)

Paso Robles, CA 93447 PAGE 1 OF 11

Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 09-09-09

SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific type of conversions. Modifications to any of the components will

void any possible warranty or return privileges. If you do not fully understand modifications or changes that will be required to complete your conversion, we strongly recommend

that you contact our sales department for more information. This instruction sheet is only to be used for the assembly of Advance Adapter components. We recommend that a

service manual pertaining to your vehicle be obtained for specific torque values, wiring diagrams and other related equipment. These manuals are normally available at automotive

dealerships and parts stores.

KIT CONSISTS OF:

No. Qty. Part

SUZUKI GEARS KIT NUMBERS

48-4160 / 48-4900 /48-6400

1. 1 GEAR SET OF 3 SETS AND SHAFT WITH GEAR

2. 1 CLUSTER SHAFT

3. 2 CLUSTER THRUST WASHERS

4. 2 CAGED NEEDLE BEARINGS

5. 1 GASKET SET

6. 3 SEALS

7. 1 O-RING

Suggested tools:

Ratchet, 12mm, 14mm & 28mm sockets

Air impact gun

Hammer

Grinder on some gear sets

Needle nose pliers

3/16" punch

Snap ring pliers

Gasket scraper

6mm Allen wrench

Straight screwdriver

Crescent wrench

RTV silicon

Bearing grease

1. Drain oil from transfer case and remove the transfer case from the vehicle.

2. Remove the 4WD indicator switch.

3. Turn the transfer case over and collect the 4WD indicator ball as it falls out of the indicator hole. This is a larger

ball than the balls removed later.

4. Use the 28mm socket and remove all three flange yokes, label them for correct re-installation.

Summary of content (11 pages)

PAGE 1
ADVANCE ADAPTERS INC. P/N: SUZUKI P.O. Box 247, 4320 Aerotech Center Way Paso Robles, CA 93447 Telephone: (800) 350-2223 Fax: (805) 238-4201 New Item: (09/09) PAGE 1 OF 11 Page Rev. Date: 09-09-09 SUZUKI GEARS KIT NUMBERS 48-4160 / 48-4900 /48-6400 KIT CONSISTS OF: No. Qty. Part 1. 2. 3. 4. 5. 6. 7.
PAGE 2
ADVANCE ADAPTERS INC. P/N: SUZUKI P.O. Box 247, 4320 Aerotech Center Way Paso Robles, CA 93447 Telephone: (800) 350-2223 Fax: (805) 238-4201 New Item: (09/09) PAGE 2 OF 11 Page Rev. Date: 09-09-09 SUZUKI GEARS KIT NUMBERS 48-4160 / 48-4900 /48-6400 5. On the bottom of the transfer case, remove the 6mm detent plug. 6. Remove the detent spring and ball by flipping the T/C over. 7. Remove the speedometer bolt and speedometer housing. 8. Remove the 7 bolts holding the front housing to the case.
PAGE 3
ADVANCE ADAPTERS INC. P/N: SUZUKI P.O. Box 247, 4320 Aerotech Center Way Paso Robles, CA 93447 Telephone: (800) 350-2223 Fax: (805) 238-4201 New Item: (09/09) PAGE 3 OF 11 Page Rev. Date: 09-09-09 SUZUKI GEARS KIT NUMBERS 48-4160 / 48-4900 /48-6400 13. As the case halves come apart, be sure to catch the small steel ball that will need to be reinstalled later. 14. Remove the cluster gear and thrust washers from the rear housing. 15. Remove the input gear/shaft and bearings. 16.
PAGE 4
ADVANCE ADAPTERS INC. P/N: SUZUKI P.O. Box 247, 4320 Aerotech Center Way Paso Robles, CA 93447 Telephone: (800) 350-2223 Fax: (805) 238-4201 New Item: (09/09) PAGE 4 OF 11 Page Rev. Date: 09-09-09 SUZUKI GEARS KIT NUMBERS 48-4160 / 48-4900 /48-6400 18. Remove the output shaft and gear assembly from the rear housing. 19. Remove the snap ring from the end of the output shaft. 20. Remove the gear. 21. Using a press, press the output shaft through the bearing. 22.
PAGE 5
ADVANCE ADAPTERS INC. P/N: SUZUKI P.O. Box 247, 4320 Aerotech Center Way Paso Robles, CA 93447 Telephone: (800) 350-2223 Fax: (805) 238-4201 New Item: (09/09) PAGE 5 OF 11 Page Rev. Date: 09-09-09 SUZUKI GEARS KIT NUMBERS 48-4160 / 48-4900 /48-6400 25. Clean the caged needle bearing that was under this gear and re-install on to the shaft with some bearing grease. Now install the new low speed gear on to the shaft. Install the gear spacer, the speedometer gear, bearing and bearing collar.
PAGE 6
ADVANCE ADAPTERS INC. P/N: SUZUKI P.O. Box 247, 4320 Aerotech Center Way Paso Robles, CA 93447 Telephone: (800) 350-2223 Fax: (805) 238-4201 New Item: (09/09) PAGE 6 OF 11 Page Rev. Date: 09-09-09 SUZUKI GEARS KIT NUMBERS 48-4160 / 48-4900 /48-6400 28. The input shaft/gear will now need the bearings removed and installed on the new shaft/gear. A press is usually needed to remove and install the bearings.
PAGE 7
ADVANCE ADAPTERS INC. P/N: SUZUKI P.O. Box 247, 4320 Aerotech Center Way Paso Robles, CA 93447 Telephone: (800) 350-2223 Fax: (805) 238-4201 New Item: (09/09) PAGE 7 OF 11 Page Rev. Date: 09-09-09 SUZUKI GEARS KIT NUMBERS 48-4160 / 48-4900 /48-6400 29. Temporarily install the cluster gear into the case halves to check for gear and case clearance. Use a marking pen to make the case for clearances. With a grinder modify the case as necessary to fit the gear. 30.
PAGE 8
ADVANCE ADAPTERS INC. P/N: SUZUKI P.O. Box 247, 4320 Aerotech Center Way Paso Robles, CA 93447 Telephone: (800) 350-2223 Fax: (805) 238-4201 New Item: (09/09) PAGE 8 OF 11 Page Rev. Date: 09-09-09 SUZUKI GEARS KIT NUMBERS 48-4160 / 48-4900 /48-6400 33. Slide the high/low shift rail onto the output gear assembly. 34. Slide the gear assembly into the center housing. 35. Install the front shift collar onto the shift fork. 36. Tap the output assembly into place using a rubber hammer 37.
PAGE 9
ADVANCE ADAPTERS INC. P/N: SUZUKI P.O. Box 247, 4320 Aerotech Center Way Paso Robles, CA 93447 Telephone: (800) 350-2223 Fax: (805) 238-4201 New Item: (09/09) PAGE 9 OF 11 Page Rev. Date: 09-09-09 SUZUKI GEARS KIT NUMBERS 48-4160 / 48-4900 /48-6400 38. Install the O-ring on the cluster pin and slide the bearings and spacer on the cluster pin. 39. Apply grease to the cluster bearings and slide the cluster gear onto the shaft assembly.
PAGE 10
ADVANCE ADAPTERS INC. P/N: SUZUKI P.O. Box 247, 4320 Aerotech Center Way Paso Robles, CA 93447 Telephone: (800) 350-2223 Fax: (805) 238-4201 New Item: (09/09) PAGE 10 OF 11 Page Rev. Date: 09-09-09 SUZUKI GEARS KIT NUMBERS 48-4160 / 48-4900 /48-6400 42. Apply silicone to the case haves and install the gasket. Slide the case two haves together making sure the thrust washer stays in place. Once the cases are aligned and slide together, install the 11 bolts back to there original location. 42A.
PAGE 11
ADVANCE ADAPTERS INC. P/N: SUZUKI P.O. Box 247, 4320 Aerotech Center Way Paso Robles, CA 93447 Telephone: (800) 350-2223 Fax: (805) 238-4201 New Item: (09/09) PAGE 11 OF 11 Page Rev. Date: 09-09-09 SUZUKI GEARS KIT NUMBERS 48-4160 / 48-4900 /48-6400 44. Install the yokes on to the transfer case and stake them to the shafts. The rear yoke is the taller yoke and is different than the other two. 43. Reinstall the steel ball in the bottom of the case followed by the spring and the detent plug. 44.