so pulled my transfer case today, and found that i had 1 of 8 transfer case bolts holding the transfer case to the mighty kong... 4 the bolt heads were gone, 3 was missing and one was still there. could have been the transfer case movement problem  so going to drill and tap them and replace all 8 bolts and see what happens...

Use a bit of lock tight so they don't work their way out.  It tends to cause the case to break for some reason. 

yea  i didnt use lock tight the first time bc i was rushing to get it together, so one worked its way out, then another and then they started snapping. seems to just have caused a chain reaction... but this time it will definetly get lock tight-ed!

got all the snapped off bolts out, accidently drilled a hole in one of the bolt holes, it went into the tcase. put some thread sealer and loctite on that bolt and seems to be holding up. but replaced all 8 bolts. loctited them in and she seems to be doing alot better now. bolts are yet to back out and that hole is yet to give me a problem. so its back to some wheelin. hopefully can get some pics of today adventure. my threads been lacking them!!!

JB-Weld is your friend. 

in order to jb weld it i would have had to split the cases and all that and i really didnt feel like doing that lol. so i just put some thread sealer on the bolt and sent it. seems to be holding up fine

They will work loose again. Sami's seem to shake bolts loose all the time. I tried all kidns of loctite with no solution. Just check all the drivetrain bolts every couple months. It will save you alot of trouble.

they do seem to do that alot! i have been. i do it every couple weeks just to be safe. especially with the one bolt bc if that works loose i'll have transfer case fluid everywhere. and i dont want that!!

but i have come up with this winters project for my sammi, many will disagree with it but im doing it bc its what i want.
-4.3L V6 that im rebuilding myself
-1ton axles
-4link, air shocks and stretching between 101"-104"
-replacing floor pan and rusted out body panels
-fuel cell
-roll cage
-possibly moving the radiator the rear with electric fans, depending on how the steering fits after the stretch
-and possibly more little things that i see as i go through the build

Interesting,you bought a lifted very capable little Samurai and were "bragging" on its abilities,how it could "out-wheel" the Jeeps in your neck of the woods.First time you try muddin with the Big Boys you got stuck and felt like the Samurai was not all you thought.So now you basically want to tear down the entire drivetrain and build a Big Boys play rig...right???These Samurai's are "niche" vehicles that by virtue of the small size/light wieght can generaly outwheel or outmanuever larger rigs,thats why WE love them!!Do what I've done,keep that Samurai like it is,go find a full size you can LIFT and mud with.Got a stock (for now) '86 Samurai 4x4 AND a '97 Dodge excab 4x4 Laramie SLT with 4:11 gears and Lockers rollin 38.5x15 Swampers TSL SX.

i do out wheel most of  the jeeps in my neck of the woods. and thats out wheel by in the trails, through rock cuts, etc.. i went muddin with 700hp mud trucks running 54"+ ag tires. it was a benefit for my friend that passed away and no one knew how bad the mud hole would be. and thats not why i want to rebuild my samurai. that is why i put 6.5:1 tcase gears. i burnt my clutch up in the mud and didnt want to keep doing that. if i wanted a mud truck i would build a full sized mud truck. but my rig will be for some mudding and alot of trails. and with where i wheel its alot of rocks, and rock climbs. the samurai's short wheel base does fine on most, but for the more challenging ones it would just flip over. and thats no good. so im stretching the wheel base, giving it stronger axles and bigger tires.

i understand why samurai's are loved, smaller, lighter trail rigs. and i love that about mine, but its short wheel base has its  disadvantages. and it still will be lighter than alot of rigs. but for my first samurai i want to build it to have higher HP, 1tons and bigger tires. and what is the point of modifying a vehicle? to make it what you want. thats what i want for this one. so when your paying for MY build, then try to tell me what to do. but until that day i will spend MY money to build MY rig how i want. and you can build whatever you want. and unless you have something helpful to say, or maybe positive feedback, you can keep your 2 fucking cents off my damn build thread!

Are you going to lift it or just cut out your fenders to keep it as low as possible and get your lift from the tires?

im going to have to lift it more, but not alot, then get the rest with cutting fenders and what not. but with stretching my WB and running full sized axles alittle more lift is okay bc of how much wider and longer i'll be compared to now. i know a few people with 1 ton jeeps stretched to 103"-104" and they are between 7-8 ft tall at the top of the roof. they arent too bad as far as roll overs. my sammi is just over 6 ft tall. and im going to be 100"-103"WB with 1tons. so i have some room to lift and still be stable.

Never seen such "explenative's" on this fourm,dude. Just sad that some of us Samurai fanatics see another Samurai being tore down ...relax!!

well im doing something alittle different than most other samurai guys. im not content with spending alot of money to build yota axles and put a 1.6, 2.0 or 1.9 deisel in it when i could get stronger axles off the start with dana 60's and more HP from a V6.

got my 4.3 V6 out of the donor s10 today. here are some pics of it. going to start tearing it apart tomorrow!