Suzuki Jimny Trail Gear Transfer Case Gear Set 60% Low Reduction Manual & Automatic Transmission (98 - 05)

Suzuki Jimny 1998-2005 Trail-Gear 60% Low Range Planetary Reduction Gears - Manual & Automatic

Upgrade the off-road capability of your Suzuki Jimny Generation 3 (1998-2005) with this Trail-Gear 60% low-range planetary reduction gear kit, designed for Jimnys fitted with either a 5-speed manual or 4-speed automatic gearbox and the earlier manually operated lever-shift transfer box.

This kit provides a 60% reduction in low range while retaining the original factory high-range gearing, making it an excellent choice for Jimny owners who want substantially lower gearing for demanding off-road driving without changing the vehicle's normal road gearing.

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 both manual and automatic gearbox models with the original lever-operated transfer box. Not suitable for later electric push-button transfer boxes.

Factory High Range Gearing Retained

Unlike reduction gear kits that alter both high and low range, this Trail-Gear planetary kit only changes the low-range gearing.

The original factory high-range ratio remains unchanged, meaning normal road driving and high-range operation retain the original transfer box gearing.

• Original high-range ratio: 1.32:1
• Modified high-range ratio: 1.32:1
• High-range reduction: 0% - factory gearing retained

This makes the kit particularly suitable for Jimny owners who are happy with their existing road gearing but want improved crawling ability when driving off-road.

60% Low Range Reduction

The substantial 60% low-range reduction provides significantly lower gearing for technical off-road driving, allowing the Jimny to crawl over difficult obstacles at much slower speeds.

This is particularly beneficial when tackling steep climbs, rocky terrain, deep ruts and other challenging off-road conditions.

• Original low-range ratio: 2.145:1
• Trail-Gear low-range ratio: 3.43:1
• Low-range reduction: Approximately 60%

Benefits include:

• Significantly improved low-speed off-road control
• Greater torque multiplication at the wheels in low range
• Reduced need to slip the clutch during technical off-road driving on manual gearbox models
• Improved control on steep climbs and descents
• Better low-range gearing for larger diameter off-road tyres
• Greater control when manoeuvring over rocks, ruts and difficult obstacles
• Original high-range gearing retained for normal road driving

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.

This kit includes a replacement planetary gear assembly, sun gear and retaining ring to achieve the 60% low-range reduction while retaining the factory high-range ratio.

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

Features

• Manufactured by Trail-Gear
• 60% low-range reduction
• Original factory high-range gearing remains unchanged
• High-strength SCM415 alloy steel gears
• Heat-treated and carburised gear construction
• Designed to improve off-road performance with larger tyres
• Significantly improved low-speed off-road control
• Replacement planetary gear assembly included
• Replacement sun gear and retaining ring included
• Includes replacement oil seals and staking nuts
• Includes Ultra Grey RTV silicone
• Suitable for 5-speed manual gearbox Jimnys
• Suitable for 4-speed automatic gearbox Jimnys
• Designed 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 or 4-speed automatic
• Transfer box type: Manual lever-operated, chain-drive transfer box
• Gear material: SCM415 alloy steel
• Gear treatment: Heat-treated and carburised
• High-range reduction: 0% - factory gearing retained
• Low-range reduction: Approximately 60%
• Original high-range ratio: 1.32:1
• Modified high-range ratio: 1.32:1
• Original low-range ratio: 2.145:1
• Modified low-range ratio: 3.43:1
• Transfer box operation: Manual shift lever

Kit Contents

This Trail-Gear planetary reduction gear kit includes:

• 1 x Replacement planetary gear assembly
• 1 x Replacement sun gear
• 1 x New retaining ring
• 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 planetary reduction gear kit. It retains the original high-range gearing and does not include the separate 24% high-range reduction gear set.

Vehicle Fitment

Suitable for Generation 3 Suzuki Jimny models fitted with either a 5-speed manual or 4-speed automatic gearbox and the original lever-operated transfer box.

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

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

Please check your vehicle's 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 planetary gearing.

This kit is designed as a direct-fit conversion for compatible lever-operated Jimny 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 conversions. Confirm the instructions cover the planetary gear installation and correspond to your particular gear kit before fitting.

Important Information

• Suitable for both 5-speed manual and 4-speed automatic gearbox models.
• Manual lever-operated transfer boxes only.
• Not suitable for electric push-button transfer boxes.
• Low-range gearing reduced by approximately 60%.
• Original high-range gearing remains unchanged.
• Designed to improve off-road gearing when running larger diameter tyres.
• Includes planetary gear assembly, sun gear, retaining ring, oil seals, staking nuts and RTV silicone.
• Professional installation or experience rebuilding transfer boxes is recommended.

Please confirm your vehicle has the original lever-operated transfer box before ordering.