SPIDERTRAX ROCK SPIDER GEARSET (RSG-001) INSTRUCTIONS.
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SPIDERTRAX ROCK SPIDER GEARSET (RSG-001) INSTRUCTIONS GENERAL DESCRIPTION The Spidertrax Rock Spider Gearset (RSG) is designed to reduce both low and high range gear ratios in a stock Suzuki Samurai transfer case. With the RSG installed, the high range is reduced by 12% while the low range is reduced by 83%. The Spidertrax RSG Kit comes with everything needed for the install. Although these instructions are very detailed, it is always a good idea to have a Suzuki Samurai OEM Service Manual handy when working on the vehicle. ~ Need an OEM Suzuki Samurai Service Manual? Call today and order one. ~ SPIDERTRAX INC ~ Phone: 303.772.0033 ~ Fax: 720.294.9950 ~ Web: www.spidertrax.com
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3 4 5
8 2
6 7 9
1. 2. 3. 4. 5.
RSG-100: RSG-101: RSG-102: RSG-103: RSG-104:
Fig. 1
Counter Gear Low Gear Input Gear Thin Shim (2) Thick Shim (2)
10 11
6. RSG-105: 7. RSG-106: 8. RSG-107: 9. RSG-108: 10. RSG-109:
Thrust Washer (2) Needle Bearing (2) Counter Shaft Large Gasket Small Gasket
11. RSG-110: O-Ring
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TOOLS NEEDED • • • • • • • • •
Basic metric socket set and 3/8 ratchet wrench Impact wrench Soft hammer/mallet 2 Jaw Bearing puller Hydraulic press Feeler Gauge Torque Wrench Circlip Remover Spidertrax Polymount Kit and HD T-Case Arms recommended.
2. Loosen speedometer gear case bolt and remove speedometer gear case with gear.
REMOVAL 1. Jack up vehicle and remove all 3 driveshafts connected to transfer case. T-case should be in 2H to aid in later reassembly. 2. Remove clamp and boot connected from transfer case shifter to transfer case. 3. Twist transfer case shifter guide counterclockwise while pushing down to allow shifter to be removed. Guide is located where transfer case shifter meets transfer case. 4. Drain oil from transfer case. 5. Disconnect speedometer cable from t-case. 6. Disconnect 4WD switch lead wire at coupler 7. Remove 3 mounting nuts connecting transfer case arms to chassis and remove transfer case with arms from vehicle. 8. Remove both transfer case arms from transfer case.
Fig. 3 3. Remove indicator light switch from front case. 4. Remove bolts securing transfer front case and remove this portion using soft mallet.
DISASSEMBLY 1. Input and rear output flange on transfer case need to be removed. Either use a special tool to lock flange in place while removing flange nut with socket wrench or simply use an impact wrench to remove flange nut. Draw off flange. Fig. 4
Fig. 2
3 5. Remove bolts securing transfer center case and rear case together. Use a Soft Mallet and tap on output rear shaft to separate center and rear case.
6. Using small punch tool and hammer, drive spring pin out of the reduction shift fork.
Fig. 6 7. Remove output shaft and reduction shift fork from case.
Fig. 5 Fig. 7
4 8. Pull out counter gear, bearings and spacer. Remove counter shaft from center case by loosening counter shaft lock plate & bolt.
11. Remove front drive clutch hub circlip and pull clutch hub off shaft by using bearing puller. When using bearing puller be sure not to damage needle bearing inside output shaft. Use small socket if necessary.
Fig. 8 9. Remove input shaft from center case by hammering thick part of case or input shaft center with soft hammer. 10. Mark input shaft bearings so they can later be reassembled in the same position. Using bearing puller, remove both bearings from input shaft.
Fig. 10
Fig. 9
5 12. Remove front bearing by using bearing puller
14. It is recommended to use solvent to clean all parts prior to reassembly.
REASSEMBLY 1. Press bearings onto input shaft. Note marking from step 10 in disassembly for proper orientation.
Fig. 11 13. Remove thrust washer and lower gear from output shaft. Note orientation of thrust washer to reassemble in same position.
Fig. 12
Fig. 13
6 2. Place Rock Spider Low Gear onto output shaft. Be sure to orient low gear so side with teeth faces shift collar. Next, place thrust washer onto output shaft. Note orientation of thrust washer from step 13 in Disassembly for proper orientation. Next, place front bearing onto output shaft so external snap ring is closest to low gear. Finally, place front shift hub on output shaft so teeth are furthest from front bearing. Using a large socket to avoid output shaft, press shift hub and bearing onto shaft.
3. Place new o-ring onto new counter shaft. Install o-ring end of counter shaft into center case. Secure to center case using counter shaft lock plate & bolt and tighten bolt to 7-12 lb-ft [9-17 N*m]. In this order, slide new thrust washer with bronze face away from center case, new needle bearing, and Rock Spider Counter Gear with larger side facing center case.
Fig. 15 4. In this order, install spacer and new needle bearing onto counter shaft.
Fig. 14
Fig. 16
7 5. While holding shift collar in shift fork, place output shaft assembly into center case.
8. Place input shaft into center case using soft mallet. You may have to slightly lift Rock Spider Counter Gear to avoid interference between it and input bearing.
Fig. 17 6. Lift output shaft assembly slightly out of center case. Position reduction shift fork onto shift collar. Simultaneously reseat output shaft assembly into center case while aligning reduction shift fork with shift shaft.
Fig. 19 9. The next two steps are for determining proper shim adjustment for both input and output shafts. To start, place a single large shim (0.013 in.) into the two bearing bores of rear case.
Fig. 18 7. Place spring pin into reduction shift fork using hammer and punch.
Fig. 20
8 10. Being careful of keeping shims in place, assemble rear case to center case. During this assembly, do not install gasket. 11. Holding center case and rear case firmly together, use a feeler gauge to measure gap between both cases. Gap should measure between 0.010 - 0.006 in. If more or less gap is needed, add or subtract shims in bearing bores of rear case and repeat steps 10-11. If unable to get gap tolerance between 0.010 0.006 in. contact Spidertrax for assistance. Once shim adjustment has been completed separate center and rear cases.
13. Assemble rear case to center case. Be careful of keeping shims in place during assembly. Tighten bolts to 9.5-16.5 lb-ft [13-23 N-m].
Fig. 17 Fig. 23 14. Place gasket onto front case.
Fig. 21 12. Apply grease onto silver side of thrust washer and place into rear case. Be sure proper shims are in place into rear case. Place gasket onto rear case.
Fig. 24
Fig. 22
9 15. Assembly front case to center case. bolts to 9.5-16.5 lb-ft [13-23 N-m].
Tighten
17. Assembly driveshaft flanges and tighten to 80108 lb-ft [110-150 N*m].
Fig. 25
Fig. 27,
16. Assemble speedometer gear into rear case.
18. Assemble 4wd switch to transfer case.
INSTALLATION
Fig. 26
1. Reinstall transfer case arms to transfer case. Tighten bolts to 13.5-20.0 lb-ft [18-28 N*m]. With these lowered gears, it is highly recommended that you upgrade to the Spidertrax HD T-Case Arms. 2. Install arms to chassis using oem rubber mounts or the Spidertrax Polymount Kit. With these lowered gears, it is highly recommended that you upgrade to the Spidertrax Polymount Kit. 3. Reconnect 4WD switch lead wire at coupler. 4. Reconnect speedometer cable from transfer case. 5. Fill transfer case with SAE 80W-90, 75W-80, or 75W-90 oil. Oil capacity is 0.8 liter. 6. Twist transfer case shifter guide clockwise while pushing down to allow shifter to be reinstalled. Guide is located where transfer case shifter meets transfer case. T-case shifter should be installed in 2H position. 7. Assemble clamp and boot connecting from transfer case shifter to transfer case.
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Figure 14-1 courtesy of Suzuki Motor Corporation
