Suzuki Jimny Trail Gear Transfer Case Gear Set 24% High Reduction Manual Transmission (98 - 05)

Suzuki Jimny 1998-2005 Trail-Gear 24% / 24% Transfer Box Reduction Gears - Manual Gearbox

Upgrade the gearing of your Suzuki Jimny Generation 3 (1998-2005) with this Trail-Gear 24% high-range and 24% low-range transfer box reduction gear kit, designed for Jimnys fitted with a 5-speed manual gearbox and the earlier manually operated lever-shift transfer box.

This kit provides a cost-effective way to improve your Jimny's gearing, particularly when running larger diameter off-road tyres. By reducing both high-range and low-range gearing by approximately 24%, it helps compensate for the increased gearing caused by larger tyres while improving low-speed off-road control.

Manufactured from high-strength, heat-treated and carburised SCM415 alloy steel, the replacement gears are designed to provide strength and durability in demanding off-road conditions.

IMPORTANT: Suitable for 5-speed manual gearbox models with the original lever-operated transfer box only. Not suitable for automatic gearbox vehicles or later electric push-button transfer boxes.

24% High Range Reduction

The 24% high-range reduction helps compensate for the increased overall gearing caused by fitting larger diameter tyres.

This can improve low-speed drivability and help restore some of the mechanical advantage lost when upgrading from standard tyres to larger off-road tyres.

• Original high-range ratio: 1.32:1
• Trail-Gear high-range ratio: 1.63:1
• High-range reduction: Approximately 24%

Please note: High-range gearing is also used during normal road driving. This conversion will increase engine RPM at a given road speed compared with the original gearing, assuming the same tyre size.

24% Low Range Reduction

The 24% low-range reduction provides lower gearing for off-road driving, helping improve vehicle control when tackling steep inclines, uneven terrain and technical obstacles.

This reduction offers improved crawling ability without the substantial gearing changes associated with more extreme off-road reduction kits.

• Original low-range ratio: 2.145:1
• Trail-Gear low-range ratio: 2.66:1
• Low-range reduction: Approximately 24%

Benefits include:

• Improved low-speed off-road control
• Increased torque multiplication at the wheels
• Better gearing when running larger diameter tyres
• Improved control on steep climbs and descents
• More manageable gearing when navigating difficult terrain
• Cost-effective gearing upgrade for off-road use

High-Strength SCM415 Alloy Steel Gears

Trail-Gear manufactures these replacement gears from high-strength SCM415 alloy steel, which is heat-treated and carburised for durability.

The kit replaces the relevant original transfer box gears to achieve the 24% reduction in both high and low range.

Designed as a direct-fit gear conversion for compatible manual gearbox Jimnys with lever-operated transfer boxes, the kit provides a practical gearing upgrade without requiring a complete replacement transfer box.

Features

• Manufactured by Trail-Gear
• 24% high-range reduction
• 24% low-range reduction
• High-strength SCM415 alloy steel gears
• Heat-treated and carburised gear construction
• Designed to help compensate for larger diameter tyres
• Improved low-speed off-road control
• Two replacement transfer box gears included
• Includes replacement oil seals and staking nuts
• Includes Ultra Grey RTV silicone
• Designed for 5-speed manual gearbox Jimnys
• Suitable for manually operated lever-shift transfer boxes
• Installation instructions included

Specifications

• Manufacturer: Trail-Gear
• Vehicle: Suzuki Jimny Generation 3
• Model years: 1998-2005 (subject to transfer box type)
• Main gearbox: 5-speed manual only
• Transfer box type: Manual lever-operated, chain-drive transfer box
• Gear material: SCM415 alloy steel
• Gear treatment: Heat-treated and carburised
• High-range reduction: Approximately 24%
• Low-range reduction: Approximately 24%
• Original high-range ratio: 1.32:1
• Modified high-range ratio: 1.63:1
• Original low-range ratio: 2.145:1
• Modified low-range ratio: 2.66:1
• Transfer box operation: Manual shift lever

Kit Contents

This Trail-Gear reduction gear kit includes:

• 1 x Replacement input shaft gear
• 1 x Replacement sprocket gear
• 3 x Trail-Safe Jimny transfer box input/output oil seals
• 3 x New staking nuts
• 1 x Tube of Ultra Grey RTV silicone
• Detailed installation instructions

Please note: This is the gear set without the planetary assembly.

Vehicle Fitment

Designed specifically for Generation 3 Suzuki Jimny models fitted with a 5-speed manual gearbox and the earlier lever-operated transfer box.

• Suzuki Jimny - 1998-2005
• 5-speed manual gearbox only
• Manual lever-operated transfer box
• Chain-drive transfer box

IMPORTANT: This kit is for manual gearbox Jimnys only. It is NOT suitable for automatic gearbox models or vehicles fitted with the later electric push-button transfer box.

Please check both your main gearbox and transfer box type before ordering, particularly on vehicles near the model changeover period or those fitted with replacement transfer boxes.

Installation Information

Installation requires removal and dismantling of the transfer box to replace the original gearing.

This kit is designed as a direct-fit conversion for compatible manual gearbox Jimnys with lever-operated transfer boxes. However, installation involves internal transfer box components, so professional installation or experience with transfer box rebuilding is recommended.

Installation Instructions:

Instructions Click Here

Please note: These instructions are supplied by Trail-Gear for their Jimny transfer box reduction gear conversion. Follow the manufacturer's fitting procedure and confirm the instructions correspond to your particular gear kit before installation.

Important Information

• 5-speed manual gearbox models only.
• Manual lever-operated transfer boxes only.
• Not suitable for automatic gearbox vehicles.
• Not suitable for electric push-button transfer boxes.
• High-range gearing reduced by approximately 24%.
• Low-range gearing reduced by approximately 24%.
• Both high-range and low-range gearing are changed by this conversion.
• Designed to improve gearing when running larger diameter tyres.
• Includes replacement gears, oil seals, staking nuts and RTV silicone.
• Gear set supplied without the planetary assembly.
• Professional installation or experience rebuilding transfer boxes is recommended.

Please confirm your vehicle has a 5-speed manual gearbox and the original lever-operated transfer box before ordering.