Installation Instructions

Transcription

1 ) Instructions Created by an: Suzuki Sidekick / Tracker "Game Changer" 4 Speed Auto to Toyota T-Case Adapter Kit (SKU# KTC-GC-21, KTC-GC-23) Installation Instructions Suggested Tools: CAUTION: Safety glasses should be worn at all times when working with vehicles and related tools and equipment. Twin Post Lift Under Hoist Jack Stand Pry Bar Torx Socket: T40 Phillips Screwdriver, #2 Upholstery Tool: Fork Style Latex Gloves: Several Pair Brake Cleaner Sockets: 12 and 14 mm Universal Impact Sockets: 10, 12 and 14 mm Allen Socket: 8mm Allen Wrench: 5mm Impact wrench Ratchet: 3/8 Extension: 3/8 Combination Wrenches: 10,12 and 14mm Torque Wrench: able to Torque 29 Ft. Lbs. 3/8 Electric (or pneumatic) Drill Angle Grinder W/Flap Disc Vice Grip Pliers Dead Blow Hammer Ball Peen Hammer Permanent Marker: White Diagonal Cutting Pliers Snap Ring Pliers External Razor Blade or Gasket Scraper Cleaning Cloths For additional copies of these and other instructions go to: and click on the Instructions tab.

2 Important Notice: Check kit contents & hardware upon delivery receipt and let us know if anything is missing. Kit Contents Number Qty Description 1 1 Forward Shift Cover Plate 2 1 PreRunner Hardware Kit (See List Below) 3 1 Oil Seal 4 1 Transmission to Transfer Case Coupler 5 1 PreRunner Adapter Plate 6 1 PreRunner Casting W/Speed Sensor Hole 7 1 Permatex Automatic Transmission RTV Gasket Maker 8 1 Permatex Gear Oil RTV Gasket Maker 9 1 Permatex High Strength Red Thread Locker 10 1 Dual Case Speedo Extension Cable

3 Important Notice: Check kit contents & hardware upon delivery receipt and let us know if anything is missing. Hardware Number Qty Description 1 8 M X40 JIS Grade M X40 mm Socket (Allen) Head Bolts 3 2 M Nuts 4 2 M X45mm Double Ended Studs 5 4 M X55mm Socket (Allen) Head Bolts 6 10 M10 Flat Washers 7 12 M10 Lock Washers 8 1 M6-1.0X16mm Bolt With Washer 9 4 M8X1.25X20mm Button Head 10 4 M8 Flat Washers mm Lock Washers 12 1 PreRunner Adapter Speed Sensor Cover Plate (SKU IG-PRSCP) 13 1 PreRunner Adapter Speed Sensor Cover Plate (SKU IG-PRSCP2)

4 Kit Component Identification PreRunner Casting PreRunner Adapter Plate Speedometer Cable Extension Oil Seal Coupler Forward Shift Lever Cover

5 Removing the Transfer Case Shifter Step 1 Place the transfer case shifter in the 4L position. Step 2 Loosen the Torx set screw using a T40 Torx socket and remove the shift knob. Step 3 Place the shifter in the N position.

6 Removing the Console & T-Case Shifter Step 4 Place the park brake lever in the applied or up position. Step 5 Remove the driver side phillips screw located toward the front of the console. Step 6 Remove the passenger side phillips screw. Step 7 Remove the driver side upholstery clip using an upholstery tool. See the next Tech Tips to see how these upholstery clips are removed. Upholstery Tool

7 Tech Tip 7 This shows the upholstery clip as it is when installed in the console. Tech Tip 7 (Continued) The first step in removing this style clip, is to push the center button in with a pick tool or small screwdriver. Tech Tip 7 (Continued) With the center button pushed in, insert the upholstery tool under the head of the clip as shown and pry the clip out. Be careful not to drop the clip behind the seat. You will need it during reassembly. Step 8 Remove the passenger side upholstery clip in the same way as before.

8 Step 9 Lift up slightly on the front of the rear console section while at the same time, lift up on the rear of the front console section Step 10 Continue lifting the rear of the front console until it clears the transmission and transfer case shifters. Step 11 Leave all the wires connected and lay the console on the passenger side floor board. Step 12 Remove the (6) screws securing the upper shifter boot using a phillips screwdriver.

9 Step 13 Remove the upper transfer case shifter boot. Step 14 Peal the lower transfer case shifter boot up exposing the shifter lock. Note: Make sure the shifter is still in the N position. Step 15 Using two fingers, press down on the shifter lock and rotate it counter clockwise about 1/4 turn. Then release finger pressure allowing spring tension push the lock upward. Step 16 With the shifter lock released, lift the shifter out of the transfer case.

10 Tech Tip 16 It may be a good idea to stuff a cloth in the shifter hole to keep dirt out of the transfer case.

11 Removing the Drive Lines Step 17 Raise the vehicle on a twin post lift according to the vehicle manufacturer and the lift safety guidelines. Step 18 Disconnect the front drive line from the front differential flange using two 14mm combination wrenches. Note: The vehicle we are working on is a highly modified X90 that has a solid front axle. Your drive line may be different. Step 19 Disconnect the driveline from the transfer case and set it aside. Note: This driveline was bolted to a transfer case flange. Yours may be a slip yoke. ( See Figure A on next page) If it is you will need to place a drain pan under the transfer case as fluid will likely run out. Step 20 Disconnect the rear drive line the same way as the front.

12 Suzuki Sidekick/X90/Geo Tracker Drive Lines Front Drive Line Slip Yokes Rear Drive Line Figure A

13 Removing the Transfer Case Step 21 Begin disconnecting the speedometer cable by unscrewing the sleeve in a counter clockwise direction using small channel lock pliers. Step 22 Once the sleeve is loose, remove the cable by pulling it out of the transfer case. Step 23 Place a block of wood (2X4X8 approximately) under the transmission oil pan and place an under hoist jack stand under the block of wood. Lift the transmission slightly until the crossmember is relieved of any weight. Step 24 Remove the transfer case brace by removing the (6) bolts using an impact wrench and a 14mm impact socket.

14 Step 25 Set the transfer case brace aside. Step 26 Remove the (6) transmission cross member bolts using an impact wrench and a 14mm impact socket. Step 27 Let the cross member drop down slightly. Step 28 Disconnect the exhaust support by pushing it forward with a pry bar.

15 Step 29 Unclip the O2 sensor wire from the wiring bracket. Step 30 Remove the transmission cross member and set it aside. Step 31 Lower the transmission an 3 to 4 inches using the under hoist jack stand. Step 32 Disconnect these two connectors. Simply depress the lock tab and pull the two halves apart.

16 Step 33 Disconnect the transfer case vent tube from the transfer case by pulling it forward away from the shifter tower. Tech Tip 33 Vent tube disconnected. Step 34 Place a drain pan under the transfer case and remove the drain plug using a 3/8 breaker bar or 3/8 ratchet. Let all the fluid drain out and reinstall the plug. Step 35 Begin separating the transfer case from the transmission by removing the (12) transfer case bolts using a 12mm universal impact socket and a 12mm combination wrench.

17 Tech Tip 35 Continued This shows 6 of the 12 bolts that are located on the driver side. Step 35 Continued This shows 5 of the 12 bolts That are located on the passenger side. Step 35 Continued This is one of the 12 bolts that is easily overlooked. It is longer than the other 11 bolts and is accessible only from above the transfer case. Step 36 Work the transfer case rearward until the transmission output splines are free.

18 Step 37 Lower the transfer case to the floor. Note: Some people would prefer to use an under hoist transmission jack for lowering the transfer case. But, it is up to you.

19 Removing the Transmission Speed Sensor Bolt #1 Bolt #2 Step 38 Begin removing the transmission speed sensor from the transmission-to-transfer case adapter by removing bolt #1 and bolt #2 using a 10 mm socket. Step 38 (Continued) Remove the Speed Sensor by pulling it straight out.

20 Removing the Transmission to Transfer Case Adapter Step 39 Place a drain pan under the transmission and remove the (6) transmission to transfer case adapter bolts using a 14mm impact socket. Tech Tip 39 This picture shows the 6 bolts that need to be removed. Step 40 Using a pry bar, separate the adapter from the transmission. Step 41 Remove the adapter and set it aside. Caution: These parts are cast aluminum and are easily damaged. Do not use excessive force.

21 Removing the Trigger Wheel Assembly Step 42 Using external snap ring pliers, release the snap ring from the transmission output shaft and remove it. Step 43 Remove the reluctor wheel and hub assembly from the output shaft. Tech Tip 43 This shows the removed reluctor wheel and hub assembly.

22 Modifying the Reluctor Wheel Assembly Step 44 Place the reluctor wheel assembly in a vice and drill out each one of the 4 locations on the reluctor wheel assembly using a 3/32 drill bit. (See next Tech Tip for drill locations) Drill each hole about 3/16 deep. Tech Tip 44 This shows the 4 locations. Step 45 Once drilled, separate the reluctor wheel from the hub using a chisel and hammer. Step 46 If the reluctor wheel was misshaped during this procedure, bend it back as close to it s original shape as possible. Caution: Do not bend the Blades.

23 Step 47 Using an angle grinder with a flap disc buffing wheel, smooth out the burrs left from the drilling process. Step 48 Insure that the hub is smooth and flat. Step 49 Reinstall the reluctor wheel hub back on the output shaft of the transmission in the same orientation as before, with the drill marks out. Be sure to align the slot of the hub with the woodruff key on the transmission output shaft. Tech tip 49 It may be necessary to seat the hub by tapping it into place with a hammer. Caution: wheel hub. Do not distort the reluctor

24 Step 50 Reinstall the reluctor wheel with the blades facing the opposite direction as before; blades should be oriented away from you. Be sure to align the slot in the reluctor wheel with the woodruff key so that the reluctor wheel is locked to and turns with the hub. Step 51 Reinstall the snap ring. Tech Tip 51 It may be necessary to tap the snap ring with a flat chisel and hammer in order to seat the snap ring completely in the groove. This is a tight fit. Step 52 Insure that the reluctor wheel does not spin on the hub.

25 Installing the PreRunner Adapter Plate Step 53 Using a razor blade, clean off any old gasket, gasket sealer or debris left on the mating surface of the transmission. Step 54 Remove any residual oil or grease from the mating surface of the transmission using brake cleaner and cloth. Step 55 To test for proper fit, temporarily install the PreRunner Adapter Plate to the transmission before continuing to the next step. Be sure the Adapter Plate is oriented with the Inchworm Logo facing you. Caution: Since the Gasket Maker, that is applied in the next step, sets up in about 10 minutes, we strongly recommend that you read through steps 56 through 66 before doing step 56. We also recommend laying out all the parts, fasteners and supplies needed to complete these steps. Step 56 Remove the PreRunner Adapter Plate and apply the supplied P e r m a t e x A u t o m a t i c Transmission RTV Gasket Maker as shown here.

26 Tech Tip 56 This shows where to apply the Permatex Automatic Transmission RTV Gasket Maker.

27 Step 57 Apply the supplied red threadlocker to one end of the (2) double ended studs. Step 58 Install the (2) studs in the top two holes. Step 59 Tighten both studs using small channel lock or vice grip pliers. Be sure to grip the stud in the non threaded area. Do not damage the threads of the stud. Tech Tip 59 If the studs will not go in all the way with pliers, you may need to use the double nut approach of tightening studs. 1. Install two nuts on the stud 2. Hold the bottom nut with an open end wrench and tighten (clockwise) the top nut with a second open end wrench 3. Tighten the stud using a box end wrench on the top nut.

28 Tech Tip 59 Continued 4. When the stud becomes tight, hold the bottom nut and remove (counter clockwise) the top nut. Then remove the bottom nut. Step 60 Position the PreRunner Adapter Plate as before. Step 61 Apply read thread locker to the threads of the (4) M X55mm allen head bolts and install them one at a time in the locations shown in the next step. Step 62 This shows the locations of the (4) allen head bolts. Note: There are no washers with these bolts.

29 Step 63 Lightly snug these bolts using 8mm allen socket. Step 64 Install a flat washer, lock washer and nut on the passenger side stud. Step 65 Install a flat washer, lock washer and nut on the driver side stud. Step 66 Tighten all (6) fasteners in a progressively tighter criss cross patter until 29 ft. Lbs. is reached.

30 Tech Tip 66 The top two fasteners will have to tightened using a 14mm crow foot, 3 extension and a ratchet or a stubby box end wrench. You will have to estimate the torque on these top two nuts.

31 Installing the Speed Sensor Step 67 Install the transmission speed sensor. It should snap into place. Be sure it is all the way in. Step 68 Apply some Permatex Automatic Transmission Gasket Maker to the threads of the speed sensor bolt. Note: Be sure to inspect the O-ring. If damaged or hard and brittle, we recommend replacing it. Step 69 Install and snug the speed sensor bolt securing the speed sensor using a 10mm box end wrench.

32 Checking & Adjusting the Speed Sensor Air Step 70 Turn the key to the on position and place the transmission shifter in neutral. Step 71 Rotate the transmission output shaft until one of the blades aligns with the sensor. Step 72 While placing moderate side pressure on the transmission out put shaft measure the air gap with a feeler gauge. The air gap should be between.005 and.011 to work properly. Step 73 If the air gap is not within specification, bend the blade in the needed direction using small channel lock pliers and measure again. Continue steps 71 & 72 until the air gap is within specifications.

33 Step 74 Repeat steps 71 to 73 on the other 3 trigger wheel blades. Step 75 This vent tube will not be used in this application. So, simply cut it off as shown here. Step 76 Additionally, this wiring bracket has no where to mount. You could build a custom bracket, zip tie it in a safe a secure place. Step 77 Place the shifter back in Park and turn the key to Off.

34 Preparing the PreRunner Adapter Casting Step 78 Using brake cleaner and a cloth, clean the mating surface of the PreRunner Adapter Plate. Step 79 Clean the forward shift cover plate area of the PreRunner Adapter Casting with brake cleaner and a cloth. Step 80 Apply the supplied Permatex Automatic Transmission RTV Gasket Maker to the shifter plate area. Step 81 Spread the gasket maker evenly.

35 Step 82 Position the supplied forward shift cover plate. Install and tighten the (4) button head allen bolts. Note: Be sure each bolt has a lock washer and a flat washer. Step 83 Apply the supplied Permatex Automatic Transmission RTV Gasket Maker to the unused speed sensor area. Step 84 Position the supplied speed sensor plate. Step 85 Install and tighten the button head allen bolt using a 5mm allen wrench. Note: Be sure the bolt has a flat washer and a lock washer with it.

36 Installing the PreRunner Adapter Casting Step 86 Using brake cleaner and a cloth, clean the mating surface of the casing. Step 87 Apply a bead of Permatex Automatic Transmission RTV Gasket Maker to the mating surface of the PreRunner Adapter Casing. Step 89 Position the PreRunner Casting against the Adapter Plate. Caution: This is a very tight fit. Even pounding with a dead blow hammer will likely not be enough to have these two parts come together. Please follow these instructions carefully. Step 90 Align the (4) mounting holes. Important Notice: Be sure to read the next Tech Tips before installing these bolts.

37 Tech Tip 90 It is optional as to which set of clocking holes you use when attaching the PreRunner Adapter Casting to the PreRunner Adapter Plate. However, for this application, we recommend using the holes indicated here. Even though this will NOT provide the greatest transfer case-to-ground clearance, it WILL result in the least amount of required floorboard modification. SEE STEP 103. Step 91 Apply red threadlocker to the threads of the (4) M10X1.25X40 bolts. Step 92 Install the (4) M X40mm mounting bolts using a flat washer and a lock washer on each bolt. Note: The lock washer should be against the head of the bolt. Step 93 Install the (4) bolts a couple of turns each to align the casting to the adapter plate.

38 Step 94 Strike the back of the PreRunner Adapter Casting with a dead blow hammer. Then snug the bolts. Continue alternately striking the casting and tightening the bolts until the two parts come completely together. Then torque the bolts to 29 ft. Lbs. Step 95 Install the supplied coupler on the transmission output shaft. Step 96 Insure that the coupler is seated all the way forward by tapping on it with the handle of a hammer. Caution: Be careful not to distort the coupler. Use a wood or plastic hammer handle.

39 Installing the PreRunner Casting Seal Step 97 Apply a thin film of Permatex Automatic Transmission RTV Gasket Maker to the outside surface of the supplied seal. Step 97 (Continued) Spread the RTV evenly around the seal. Step 98 Using a ball peen hammer, drive the seal evenly and squarely in the PreRunner Casting until it is flush with the casting surface. If you have a seal driver or appropriate size socket (with and outside diameter a little smaller than the seal) the seal may go in easier. See next photograph. Tech Tip 98 This shows the seal properly installed.

40 Test Fitting the Transfer Case Clearancing the Body Step 99 Lower the under hoist jack stand a little. Install the transfer case with out the gasket or gasket maker to check for body clearance. Step 100 Install one or two bolts to keep the transfer case temporarily secure. Step 101 Raise the under hoist jack stand to see if the transfer case hits the body. If it does, mark the area of the floor pan needing to be clearanced. Step 102 Remove the transfer case.

41 Step103 Clearance the body by using a dead blow hammer. Step 104 It may also be necessary to use a ball peen hammer as well to gain the necessary clearance. Tech Tip 104 This is what ours looked like when done. If you are confident that you have gained enough clearance, continue to the next step. If there is question, reinstall the transfer case and check body clearance before continuing. Step 105 Once you are sure there is sufficient clearance between the transfer case and the body, check the transfer case gasket for fit.

42 Step 106 Apply Permatex Gear Oil RTV Gasket Maker to both sides of the transfer case gasket. Tech Tip 106 Apply a liberal amount of gasket maker to both sides of the gasket. Then, with latex gloves on both hands, smear the gasket maker on both sides of the gasket at the same time. Tech Tip 106 Continued It is messy, but it s fast. Step 107 Place the gasket on the PreRunner Casting. Then change out your latex gloves.

43 Step 108 Reinstall the transfer case. Step 108 Start the (4) hex head M10X1.25X40mm bolts. Leave them hand tight for now. Be sure to install a lock washer and flat washer on each bolt. Step 109 I n s t a l l a n d s n u g t h e ( 2 ) M10X1.25X40mm allen head bolts in the top two holes. These (2) bolts require only a lock washer without a flat washer. Step 110 Tighten all (6) bolts in a progressively tighter criss-cross pattern until 29 ft. Lbs. Is reached. Note: It may not be possible to get a torque wrench on the top two allen head bolts, so you will need to estimate the torque.

44 Installing the Speedometer Cable Step 111 Lower the back of the drivetrain assembly (engine, transmission and transfer case) several inches. Step 112 Install the supplied speedometer cable extension in the transfer case. Step 113 Snug the retainer ring. Note: point. No need to fully tighten at this Step 114 While observing the speedometer extension, slowly raise the drive train assembly.

45 Step 115 Stop raising the drive train assembly when the speedometer extension contacts the body. Step 116 Mark the point of contact using a permanent marker. Step 117 Remove the speedometer extension. Step 118 Dent the floor panel creating clearance for the speedometer cable extension using a block of wood and a hammer.

46 Tech Tip 118 You could also use a steel bar and hammer for clearancing the floor panel. Step 119 Reinstall the speedometer extension on the transfer case and tighten the retainer ring. Transfer Case Frame Underside Step 120 Continue raising the drive train assembly until the transfer case is at proper height. (See the next Tech Tip for proper height) Tech Tip 120 Proper height is where the transfer case is at or above the under side of the frame. Caution: If proper height cannot be achieved without kinking the speedometer cable extension, additional floor panel clearancing will be necessary.

47 Step 121 C o n n e c t t h e o t h e r e n d o f t h e speedometer cable extension to the existing speedometer cable. Conclusion This concludes our instructions. You will need to purchase a suitable transfer case mount and custom build or purchase a suitable transfer case cross member. Additionally, you will need to modify the existing drive lines or have new ones made. Thank you for allowing us to help you with this project. We hope it went well and wish you the best in completing the rest of the project. Step 122 After, installing the transfer case mount, cross member and drive lines, install the shifter and console in reverse order of removal. It may be necessary to modify the console and the floor panel to accommodate the Toyota T-Case shifter.

48 As always, If you experience any difficulty during the installation of this product please contact Inchworm Gear Technical Support at M-F 8:00am-5:00pm MST. Thank you for purchasing from Low Range Off-Road. These instructions are designed as a general installation guide. Installation of many Low Range Off-Road products require specialized skills such as metal fabrication, welding and mechanical trouble shooting. If you have any questions or are unsure about how to proceed, please contact our shop at or seek help from a competent fabricator. Using fabrication tools such as welders, torches and grinders can cause serious bodily harm and death. Please operate equipment carefully and observe proper safety procedures. Rock crawling and off-road driving are inherently dangerous activities. Some modifications will adversely affect the on-road handling characteristics of your vehicle. All products sold by Low Range Off-Road are sold for off road use only. Any other use or application is the responsibility of the purchaser and/or user. Some modifications and installation of certain aftermarket parts may under certain circumstances void your original dealer warranty. Modification of your vehicle may create dangerous conditions, which could cause roll-overs resulting in serious bodily injury or death. Buyers and users of these products hereby expressly assume all risks associated with any such modifications and use. Revised 07/14/15 Copyright 2015 Low Range Off-Road, LC All Rights Reserved