Vitara Gear Reduction

[christover1]

If acessing the bolts is hard,
try lowering gearbox down, rather than removing it,
may give you enough space to get tools in to remove selector housing,
and get to the last bolt

[Scythe]

Well, it's days later and I can confirm you do have to remove the gearbox with the transfer case on a manual Vitara; all for the sake of one bolt under the gear shift tower housing which has to be removed in order to get the bolt. It may be possible to remove the shift housing without removing the gearbox, but this did not seem to be a realistic or achievable option. I have finally completed removing the box and case and inserting the new gears in the transfer case, and I would not assess it as a simple task. I am not new to mechanics, but I found this task to be challenging especially as the instructions were often ambiguos or lacking in detail. I am still not certian the outcome will be a success as there are so many things that may not be right. Unfortunately the only way to find out is to put it all back together and try it. I must say I am not looking forward to getting the box and case back in. I did buy a new
(large) trolley jack and made a mount to carry the assembly once I found out I had to remove the gearbox as well as the transfer case. Despite this, it was still a tricky and nervous task getting the assembly out. Although they are smallish, the box and case together make a long and heavy assembly. Without a suitable jack or transmission lifter, this task could be quite a dangerous task.

All that said (and assuming all is sucessful) I must admit I would not find it too difficult to replicate the procedure. However, this is one task I hope to never have to do again. Fingers crossed, and hoping it is all worth it.

I hope this is useful to anyone considering this procedure in the future.

Scythe

[christover1]

I was very nervous, too.
Still am, as not done much driving on the new gears.
I am sure hoping I never need to do it again

Don't be surprised if they a bit "sticky" till oil works it way around.
Mine locked the rear wheels when I slowed down,
so drive slowly at first.
Running quiet and smooth, now

Change oil after a few hundred K. To make sure all bits are out.

I used a couple of heavy duty ratchet straps as lifters.
But it can be a little risky, right tools is best.

[Scythe]

Thanks Christover.

If I survive the gearbox replacement, I will let you know how it goes.

Scythe

[gwagensteve]

It is possible to get the transfer off without dropping the gearbox out altogether, but it is terribly hard. A long extension on a 1/4" ratchet down through the manual shifter hole. I speak from bitter experience. It's much easier with an auto, with no shift housing in the way.

Steve

[christover1]

My first proper off road drive was Sunday,
it was well worth the effort.
Especially in an auto,
going down steep hills, never needed to brake.
No more blasting up hills to keep engine revs right.

I think my Vit will love me more,
now I can drive it more kindly.

best of luck,
hope we see you on the tracks some day

[Scythe]

Well..... It is in and seems to be working fine. The reduction is evident. The car will now idle up low grade hills at a speed where I can get out and slowly walk beside it. Kewl, but not recommended. More testing and tightening, and then we are off to the bush.

Scythe

[gwagensteve]

Excellent!

Steve.

[Scythe]

Just to wrap this up, here's my verdict. I have just spent a few days wheeling around the Walhalla (VIC) area with a large group of vehicles. I will state with no reservation that the difference from the transfer case is pulpable. I would rate this mod as my top 3 requirements for anyone intending to use a Vitara as a real 4WD. Tyres, Suspension, and gear reduction, working together make the vehicle safer, more controllable, and significantly more capable in the bush. It is a fair cost and a bit of effort to do the gear reduction, but it is well worth it. My vehicle was easily outperforming a modern Jeep and Discovery, even though both had significant modifications, and 33' tyres. It also kept up with the big and heavily modified Landcruisers and Patrols. Not too shabby for the runt of the litter with 29" tyres and no diff locks. I must admit, footprinting is very important with a lack of ground clearance, and that I would never consider a Vitara with limited mods as a trail slayer. But with at least these three mods, and some reasonable driving, I am suprised what they will do. This opinion comes from significant experience driving large Patrols, Landrovers and Cruisers over many years. The vehicle is small and fun, and suitably capable for the VIC 4WD conditions. I would recommend this vehicle and this mod to anyone with a similar intent, provided they are willing to leave the luxury camp items behind.

Cheers

Scythe

[christover1]

Very cool indeed.
Well done.

I finaly got to try my gears in the real world.
I feel just as excited.