Advance Adapters 48-6400 - 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: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 09-09-09
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.
KIT CONSISTS OF:
No.
Qty. Part
SUZUKI GEARS KIT NUMBERS
48-4160 / 48-4900 /48-6400
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.