OK check this had my Sammy since about Feb of '08 wrecked it not Ive got all kinds of problems Ive swapped the frame, only mods on it is my Weber and SPOA (spring over i don't know if thats the right abbreviation) also my 31's. my 1st time on a real trail i drowned it (need fuel infected soon) so i changed my oil in my diffs but not my transfer case for some reason so now I'm rolling on a 2-D transfer case. and i miss my 4-D dearly. so any links to a how to rebuild transfer would b much appreshated 


also when i drive it and i hit the gas a little it will fall on it face then will get sudden burst of jumping about breaking my neck, i think its my PVC according to my Sammy manual, or just some trash in my fuel line any advise on this would b nice as well.

oh yea by the way I'm new on ZUKIWORLD, should b nice to chat with my fellow Sammy and tracker people.   

Chilton manual?

if u recommend it ill go look for it. i have a Haynes manual for samurais and trackers. thanks man.

Here's a blow up of the T-case
http://i49.photobucket.com/albums/f261/rellim87/T-caseBlowup.jpg

This is pretty much the only thing i used to re-build and re-gear my T-case, its a very simple thing to do.

I also found this pretty helpful for working on it.
http://trail-gear.com/tech/zuk65gears/index.html

If you need anymore info just let me know and i can try to get some.

Oh and the Suzuki Samurai Factory (ZukboysFSM) manual is way better than any Chiltion or Haynes manual.

Hope that helps


Amilla

OK thanks allot amilla, every wheres Ive read and everone Ive talked to said it was hard to rebuild.
to be honest i think its just remembering what goes where.
   and i got a big question is a press really needed I'm sure i could get access to one I'm just curious.

Good writeup at:
 http://www.trail-gear.com/pdf/suzuk-tcase.pdf

Also check the front output shaft on the T-case.  Early models were prone to stripping but can be replaced with the output from the later models. 

If I remember correctly, you can go to ACKs-faq.com and search for "factory service manual" or "FSM" and there's some links to it.

www.suzukiinfo.com   theres a downloadable FSM for samurais and bunch of other extra stuff

OK thanks allot amilla, every wheres Ive read and everone Ive talked to said it was hard to rebuild.
to be honest i think its just remembering what goes where.
   and i got a big question is a press really needed I'm sure i could get access to one I'm just curious.

A press makes life much easier, but according to trail-gear you can re build them with a hammer and some brass dowels. I wouldn't want to do it that way, there's no where near the control of a press.

Trail-gear has a video about installing new bearings and gears in the samurai T-case, but i haven't been able to find it again.


Amilla

Quote from: skeeter1990 on December 22, 2008, 11:20:53 AM

OK thanks allot amilla, every wheres Ive read and everone Ive talked to said it was hard to rebuild.
to be honest i think its just remembering what goes where.
  and i got a big question is a press really needed I'm sure i could get access to one I'm just curious.

A press makes life much easier, but according to trail-gear you can re build them with a hammer and some brass dowels. I wouldn't want to do it that way, there's no where near the control of a press.

Trail-gear has a video about installing new bearings and gears in the samurai T-case, but i haven't been able to find it again.


Amilla

OK what r brass dowels? and I'm sure theres a place that will let me pay then 2 use their press if i cant find one that is owned by all my mentors in mechanics

autozone rents tools they might have some type of press. i know when i was a apprentice at a machine shop we use to get alot of guys coming in to press stuff out or cut something. we charged 5 bucks to press something out and in, if it was small like a sammi t-case.

talking about those days at that shop thats how i fell in love with samurais. 2 of the guys there had them. one was a 2wd with a 350 in it and the other was 4wd lifted and accessorized with all calmini items

wow i was thinking more like 15 or 20 bucks to use it but im willing to go that high any how.
yea me and my buddy r building a 2wd he just got done putting yota running gear under his with some 36' hawgs, and we r gonna start building a 66' chevy c-10.