"HOW TO" links for suzuki's

Gear calculators
www.grimmjeeper.com/gears.html

diff ratios
http://forum.difflock.com/viewtopic.php?p=27476...highlight=#274761

Nats Welded Rear Diff Writeup
http://forum.difflock.com/viewtopic.php?t=27773

Fitting a LockRight Difflock.
http://www.nitromax.nl/SAMLOCKER.HTM

Faulty Lockright Locker?
Maybe it needs shimming correctly?
http://forum.difflock.com/viewtopic.php?t=20336

How to change rear wheel bearings:
http://forum.difflock.com/viewtopic.php?t=8760&...ght=wheel+bearing

Really Useful Part Numbers
http://forum.difflock.com/viewtopic.php?t=11051

Rear Diff Oil Seal
http://forum.difflock.com/viewtopic.php?t=14086

How to fit UJ's (universal joints)
http://forum.difflock.com/viewtopic.php?t=9546&...ght=wheel+bearing

UJ Info
http://forum.difflock.com/viewtopic.php?p=174775#174775

AISIN Hub Re-Build Guide
http://orc.off-road.com/offroad/article/articleDetail.jsp?id=399668

Propshaft extension writeup
http://forum.difflock.com/viewtopic.php?p=140134#140134

Vitara and Grand Vitara Drive Ratios
http://suzuki-grandvitara.info/cms/content/category/7/34/64/


Body Lifts

Body Lift How To
http://www.roadlessgear.com/html/techarticles/bodylift/

Bodywork mods and welding

MOT Spec Welding guide
http://forum.difflock.com/viewtopic.php?t=22977


Brakes

Rear disk brake conversions:
http://forum.difflock.com/discus/messages/8/44363.html
http://www.off-road.com/suzuki/tech/backplate.htm
http://www.off-road.com/suzuki/tech/welddiscs.htm
rear disc write up from suzuki club uk
http://www.suzukiclubuk.co.uk/reardiskconversion.html

Bleeding Brakes
http://forum.difflock.com/viewtopic.php?p=73648...;highlight=#73648

Servicing Calipers
http://forum.difflock.com/viewtopic.php?p=72124...;highlight=#72124
http://forum.difflock.com/viewtopic.php?p=49082...;highlight=#49082

Really useful Numbers
http://forum.difflock.com/viewtopic.php?t=11051


Carburettors

Aisin carb strip down and clean guide
http://forum.difflock.com/viewtopic.php?t=7948

SU Carb Conversion
http://forum.difflock.com/viewtopic.php?p=165433
http://suzuki.off-road.com/suzuki/article/artic...ail.jsp?id=277598

Subaru Carb Conversion
http://forum.difflock.com/viewtopic.php?p=177530#177530

Weber carb anti-stall mod:
http://bbs.zuwharrie.com/content/topic,11445.0/all.html
http://suzuki.off-road.com/suzuki/article/artic...ail.jsp?id=277598

Electrical

Clicky Starter Fix
http://www.off-road.com/trucks4x4/article/artic...ail.jsp?id=277618
http://www.izook.com/reviews/clicky_fix/clickyfix.htm

Starter Motor Rebuild.
http://bbs.zuwharrie.com/index.php/topic,30428.0.html

Spanish SJ Wiring Info
http://www.the12volt.com/info/diagrams.asp

Roof Light Ideas
http://forum.difflock.com/viewtopic.php?t=10157&highlight=

Vitara Spotlight Wiring
http://forum.difflock.com/viewtopic.php?t=6393&highlight=

Norv's Mk2 Golf Headlights into an SJ write up:
http://forum.difflock.com/viewtopic.php?t=26348

Tow bar diagrams 7 and 13pin
http://forum.difflock.com/viewtopic.php?p=300471#300471

Indicators / Sidelights into Bonnet by d86sta
http://forum.difflock.com/viewtopic.php?t=16329

spanish headlight switchgear clean up
http://forum.difflock.com/viewtopic.php?t=35091

1991-2000 transit diesel 90amp with vac pump alternator.
http://forum.difflock.com/viewtopic.php?t=42560...ransit+alternator

Engine Conversions

Peugeot Diesel Mounts and Gearbox.
http://forum.difflock.com/viewtopic.php?p=226819#226819

VW Diesel Fit
http://www.tomsebooks.com/DieselSamurai.htm

1600 engine AND Powersteering into SJ
http://forum.difflock.com/viewtopic.php?t=5438&highlight=pas

Fitting 1600 engine in SJ
http://forum.difflock.com/viewtopic.php?p=4387

Fitting 1600 engine without conversion plate
http://forum.difflock.com/viewtopic.php?t=6804&...hlight=conversion

Wiring 1600 injection
http://www.yankeetoys.org/mini4x/efiswap/efiswap.htm

Where to by pipe work sometimes needed for conversions:
http://www.nfauto.co.uk/gates.htm


Engine mods/General Info

how to fit a vit rad in an SJ
http://forum.difflock.com/viewtopic.php?t=45278

Vitara 1.6 Sump modification
http://forum.difflock.com/viewtopic.php?t=25470...hlight=sump+++oil



Fuel System Generals

Fuel tank Ideas
http://forum.difflock.com/viewtopic.php?t=17323

Replacing your worn out mechanical fuel pump
http://forum.difflock.com/viewtopic.php?t=32247



Interior Modifications

Door Pockets (Keep those Sandwiches safe!)
http://forum.difflock.com/viewtopic.php?t=12454...208fa50f13f6ae20f


Rock Sliders and Armour

Box Section Sills
http://forum.difflock.com/viewtopic.php?t=17848

Tubular rock sliders nerf bars build
http://forum.difflock.com/discus/messages/8/46255.html

Petrol Tank Guard
http://forum.difflock.com/viewtopic.php?t=6817


Security

Cheap Suzuki Alarm system
http://forum.difflock.com/viewtopic.php?t=9375&...5560edaeed52461a2


Service Manuals

Full service manual for 413:
http://www.4x4.in.th/manual_sj413

Grand Vitara Service manuals
http://www.auszookers.com/uploads/downloads/vitara/SQ420WD.pdf

Vitara Service manual (1 of 2)
http://www.auszookers.com/uploads/downloads/vitara/SQ416_1of2.pdf
(2 of 2)
http://www.auszookers.com/uploads/downloads/vitara/SQ416_2of2.pdf


Speedo Recalibration
http://forum.difflock.com/viewtopic.php?t=10988


Steering

Mercedes Steering Arm info;
http://forum.difflock.com/viewtopic.php?t=15553

Hi-steer conversions:
http://www.zukikrawlers.com/showthread.php?t=83...ighlight=mercedes
http://www.wazuks.com/forum/viewtopic.php?t=193...ighlight=mercedes


Suspension

coils
*May* be of some use to someone planning coils / Vit solid axle swap etc. Or just for amusement
http://www.racingaspirations.com/macphersongeometry.php


Spring Perch Over Axle Guide (SPOA or SOA)
http://www.zukikrawlers.com/showthread.php?t=174

Bam Bar/Anti Wrap/Traction Bars
http://forum.difflock.com/viewtopic.php?t=25867
http://forum.difflock.com/viewtopic.php?t=14699...ghlight=axle+wrap

Drop Shackles/Missing links
http://forum.difflock.com/viewtopic.php?p=131069 - Also Discuss' Rears Up Front
http://forum.difflock.com/viewtopic.php?t=10037
http://forum.difflock.com/viewtopic.php?t=1647&highlight=rascal
http://forum.difflock.com/viewtopic.php?t=10037

Quick Disconnect Anti Roll Bars
http://forum.difflock.com/viewtopic.php?t=10914



Transfercases and Gearboxes

Transfercase Buildup VIDEO
http://www.trail-gear.com/videos/samurai-tcase.wmv

RockLobster:
http://ironbark.bendigo.latrobe.edu.au/~jeff/xfer2.htm
http://www.mallo.nl/english/4.16.htm
http://www.geocities.com/Baja/Outback/3574/Rocklobster.html
http://www.suzukiclubuk.com/rocklobster.html
http://moose.ca/~slowzuki/slowzuki/tech_info/su...t-cases/index.htm (information about standard 410 and 413 cases and how to tell them apart)

Transfer Box Cradle
http://forum.difflock.com/viewtopic.php?t=1604

Twin Gearboxes (SJ/Samurai):
http://www.suzuki-samurai.nl/volvo/volvo-eng.html (using a Volvo box)

Twin Transfer Box's on a Vitara
http://forum.difflock.com/viewtopic.php?t=23752

Mating a Sj t box to a Vit gearBox
http://forum.difflock.com/viewtopic.php?t=31904



Wheels and Tyres

Tyres and Rim Widths
http://forum.difflock.com/viewtopic.php?t=18311

What wheels will fit my SJ? Pcd Info
http://forum.difflock.com/viewtopic.php?t=15579&highlight=pcd


Winches

Mid-vehicle mounted winch:
http://www.ebroadcast.com.au/ecars/Foers/Winch.html
http://www.4wdonline.com/Foers/Winch.html
http://www.red-ibex.com/vector_winch_system.htm


Pay and play sites

http://www.paynplay.co.uk


And if you cannot find it in here, then try;
Other Suzuki 4x4 Information Resources


Suzuki Modification and Accessory Suppliers
http://forum.difflock.com/viewtopic.php?t=21649

The Suzuki Info Bible!
http://www.acksfaq.com/

MOT manual:
http://www.motuk.co.uk/manual/contents.htm

http://www.suzukitech.org.uk/

http://www.suzukiinfo.com/

SUZUKICLUBUK

http://suzuki.off-road.com/suzuki/article/artic...ail.jsp?id=277595

Jimny Info
http://www.jimny4x4europe.com/

Service Manuals

Jimny
http://www.4x4.in.th/manual_jimny/index.html

Vitara
http://www.4x4.in.th/manual_vitara/index.html

LJ
http://www.4x4.in.th/manual_lj/index.html

Suzuki Acronyms and Glossary

SPOA - Spring Perch Over Axle
RUF - Rear springs Up Front
SAS - Solid Axle Swap
LSD - Limited Slip Diff
SJ - Small Suzuki 4x4
LJ - Smaller Suzuki 4x4, the predcessor to the SJ
OEM - Original Equipment Manufacturer
OME - Old Man Emu - Suspension Manufacturer
EGT - Exhaust Gas Temperature



Useful Numbers
Handbrake Cable OEM# 54681A83600

1300cc SJ flywheel spigot bearing number 6200 2RSH (2 rubber seals)

Inlet Manifold Gasket (Metal type, Genuine Part): Part No: 13119-63B11

410 trafnser box rebuild parts list....
SJ410 Transfer Box
Rebuild Parts list

Gasket part numbers –
(Bought from main dealer)
Main Case - U29525A80050 x1
Front Case – U29535_80050 x1

Seal Part number/sizes –
38x50x8_TC R23 NBR x1 (simplybearings.com)
OS38x60x08 x2 (bearingboys.com)

Bearing sizes –
6306 NR circlip grooved x1
63-22X_NSL x1
62-28 2RS x3
bearings sizes recognised by all bearing supliers.

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removing an sj front clip

disconect all wiring from the headlights, inicators, horn and you will also need to disconect the oil sender wire this can be found just forward of the exhaust and about half way down the the block

you then need to unclip the brake pipes on the drivers side inner (right hand drive) wing as there part of the main clip

the you can find all the bolts marked in red on the pic belown and remove them. the arows are the lower door hinges and hidden bolts
dont forget when you open the doors you will find a singel bolt on both sides this is the hidden bolt... removeing the doors to get to the bolt is best as you have to take off the lower door hinge anyway

u have certainly done your homework marty......

most useful

It is truly amasing what you can find on the internet!
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But i cant be arsed to look for all the info, so i just copied and pasted it from Difflock

good old copy n paste i love it
keep up the good work shame its a zuk though lol