Advance Adapters 48-6400 User Manual

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: [phone] Fax: [phone] Page Rev. Date: 09-09-09

SUZUKI GEARS KIT NUMBERS

48-4160 / 48-4900 /48-6400

KIT CONSISTS OF:

No. Qty. Part

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.

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.

ADVANCE ADAPTERS INC. P/N: SUZUKI

P.O. Box 247, 4320 Aerotech Center Way New Item: (09/09)
Paso Robles, CA 93447 PAGE 2 OF 11
Telephone: [phone] Fax: [phone] 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. Please note bolt
locations.

9. Remove the front housing.

10. Remove the cluster shaft locking tab.

11. Remove the 11 bolts on the main case assembly.

12. Using a small hammer, tab the two case halves apart.

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.

ADVANCE ADAPTERS INC. P/N: SUZUKI

P.O. Box 247, 4320 Aerotech Center Way New Item: (09/09)
Paso Robles, CA 93447 PAGE 3 OF 11
Telephone: [phone] Fax: [phone] 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. Remove the cluster pin and needle bearings.

17. Remove the shift fork assembly.

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.

ADVANCE ADAPTERS INC. P/N: SUZUKI

P.O. Box 247, 4320 Aerotech Center Way New Item: (09/09)
Paso Robles, CA 93447 PAGE 4 OF 11
Telephone: [phone] Fax: [phone] 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. Remove the bearing, gear spacer & high speed gear.

23. Under the gear is a caged needle bearing and a shifter hub that must also be removed.

24. Turn the shaft assembly over and press the low speed gear off the shaft. The bearing keeper bearing speedometer
gear and gear spacer will be removed first. Stack these components as they come off to aid in re-assembly.

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.