Putting in lower transfer case gears and really getting on the throttle can sometimes damage the front output shaft. This results in a loud popping noise under load and is detrimental to the life of the output shaft. Repeated popping of the front output shaft gear will result in gear failure and loss of power to the front axle. In 1994 Suzuki upgraded the output shaft to a heavier duty version and stopped using the older style shaft that was prone to failure.
These later style shafts are a drop-in replacement for 1986-1993 transfer cases. You can see the difference in the picture to the right - the updated version is on top and the old style is shown below it. This upgrade is especially good for transfer cases that have lower-than-stock gearing in them because the lower the gear, the higher the torque load going through the gear.
The front output gear can be installed without fully disassembling the transfer case. Only the front output cover needs to be removed for installation. Install the updated gear now and keep the older gear in your tool box as a trail spare.
Note: Includes high-quality output shaft pilot bearing.