anybody making a heavy duty fornt output for a sami case?
keep hurting mine, 3rd time i have killed it. once it pops loose once, it will then ratchet anytime moderate load is applied.
once i broke the dick off, and that caused the bearing to get loose causing it to ratchet.
have tried shimming on somehwat more into the case betweeen the shaft adn the bearing, and that didnt last well(but this was with a worn gear that was ratcheting.)
with a new gear, fornt bearing, and shimming it towards the coupler will it hold more pressure?
t only breaks when i load the front end REALLY hard, it then spreads the case somewhat, pops the gear form the coupler, and then its all over from there. the coupler and the gear both have wear on there engaging surfaces.

anybody make a billet gear, or shiming a new gear my best option?
thanks

www.trail-gear.com makes a "heavy duty" one. It is actually just a stock one which the factory upgraded with a thicker 'big' gear, that way the collar has more area to spread the load across.
I'm sure you could send one to bobby long to get it cryo'd or heat treated.

Gearing, tires, and engine you running?

Call brent at Trail Tough, he has the Heavy Duty ones.

If you need one quickly then any Suzuki dealer will be able to get one for you for under $100....if you have a dealer nearby. The Suzuki part # is 29151-80051 .
We also have them here.

HTH

Sean DeVinney
AFTERMARKET4X4@cox.net

Where ya been Zach?

once i broke the dick off,...

Man that's gotta hurt. Remind me not to wheel with you.:D

also flip the shift collar over so it has a fresh surface to catch on to'
i just got doen fixing this on one of mine
make sure to put a new shaft it also
the dealer is cheaper and it is the same part that everyone else uses also

There are two problems I think. 1) the problem of not being engaged deeply enough (the new shaft fixes that) and 2) the bearing end breaking off

I read about the breaking problem... I just can't clearly remember it. Think a fella at Petroworks suggested it. Has to do with axle wrap in the front? Interference with the cross member? U-joint binding? It isn't simple torque though. It was mentioned on here or POR.

Hey!
> also flip the shift collar over so it has a fresh
> surface to catch on to'

Good idea! I'll do it when I get my new shaft.

well, put the new stuff in it, went and climbed a tractor tire and it poped.
took it apart, turns out i bent the whol shift rail, and broke part of the where the ball on it detents into its housing, so udner load the detent would not hold, and the collar would slide back. dont havea spare housing, and need it go go this week, so i just took the old shaft and collar and made it "full time 4x4" with a collar fully welded to the output gear, and the shift fork removed.

Where ya been Zach?

around, working 50 hours a week at the day job, and modding and repairing cars trucks and diesels nights at weekends at my own shop while trying to keep the zuki going and building my zuk powered jeep....