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Sector 4 Offroad's 'Overbuilt Output' Information
Interested in learning more?
This page will cover some in-depth and technical information about our Overbuilt Output for the SJ413 Suzuki Samurai. Some of this is helpful to read even before you decide to purchase one.
We designed our Overbuilt Output as a way to primarily strengthen up the front of the Samurai transfer case. The factory aluminum casting is full of imperfections and is paper-thin. Suzuki added extra casted-in gussets around the bearing area in an effort to improve its strength, but without changing the entire design, adding a significant amount of strength to the part was not possible. This essential "redesign" would have cost too much. We decided to do it ourselves.
The kit comes with a new Billet 6061 T6 hardened aluminum output housing. No castings here. We start with a chunk of aluminum, and CNC machine it to the shape we want. We run an inside milling operation, outside milling operation, and bearing area detail operation, along with a final fly cutting on the face where the seals for the shifter shafts will seat. This assures perfect flatness. Suzuki also adds in an oil passage so the front bearing is never starved for oil. We have added the same passage to our front housing. All of the surfaces are machined, and the gasket area on S4's housing is fly cut for flatness, and accepts the factory dowel pins (we may offer stainless dowels in the future).
The next area we will focus on is all of the detail items that link the shifter to the transfer case. The Overbuilt Output is cable-controlled. We supply two control cables for shifting, along with a bracket that holds the cables underneath the truck. This bracket sits inside the recess for the transmission mount. Longer bolts are supplied to install this piece. Cables route through it, and attach to the transfer case via a forged clevis. The shift rods come out of the transfer case and through the housing; they have an adapter (like a bushing with a tab welded on) that the clevis on the cable connects to.
On the other end of the cables, inside the truck, the all new V2R Twin Stick shifter tower is a compact unit. The upper bracket to hold the cables is integrated into the front of the tower. The shifter tower itself is made from aluminum, and fully able to be taken apart and repaired or modified, without having to buy an entire different shifter. The shifter sticks are solid stainless steel, TIG welded and supplied with stainless spherical rod ends at the bottom (replaceable) and stainless threads and jam nuts at the top, where the shift knobs screw on. This means NO RUST!
Shift knobs are available in black plastic, aluminum, stainless steel, regular steel (don't know why anyone wants that, but its an option) and solid brass. We can also modify anything on the shifter you want, for example, flattening the top of the knobs, or drilling a different mounting bolt pattern in the base. Specify when you order.
This kit is expensive to manufacture, contains all custom made parts, and only top-quality materials are used. We strive to be different, and offer parts you can be proud to own! No more chinese-quality parts. Everything we make at Sector4 is MADE IN THE USA! All of our ideas are our own, and we will continue to try different things, and take the Suzuki community to a new level!
If you have any technical questions about the Overbuilt Output, send us an email or call us.
info@S4Offroad.com or (732) 567-9228
Pre-production Overbuilt Outputs mid-machining
Back side of a half-finished Output housing
V2R Twin Stick Shifter Tower with opt. Solid Brass Knobs
V1 Shift tower with V1 Output housing
A milestone! Our first fully completed output housing mocked up on our test case
Test Subject #3 installed in test Samurai. This is using factory transfer case mounts. We offer fully custom tubular cradles, if you need a cradle solution.
WE HAVE LINKAGE DRIVEN TWIN STICKS THAT USE THE OVERBUILT OUTPUT HOUSING. THIS KIT IS AVAILABLE NOW FOR $1020.00. THESE TWIN STICKS DONT USE A SHIFTER TOWER OR CABLES, THEY USE A DIRECT LINKAGE SETUP. IF YOU ARE INTERESTED IN ORDERING A SET OF THE LINKAGE TWINS, OR JUST WANT SOME MORE INFORMATION, PLEASE FEEL FREE TO CALL US AT (732) 567-9228 AND TALK TO MATT.
OVERBUILT OUTPUT KIT NOW OFFERED AT $1450.00
LINKAGE OUTPUT KIT AVAILABLE FOR $1020.00