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Samurai Transfer case, drive-shaft, differential gearing help

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Samurai Transfer case, drive-shaft, differential gearing help
« on: October 06, 2012, 01:15:31 PM »
I have a mint 1987 Suzuki Samurai that i have started to build into a crawler.  I first started with a Calmini 5" SPUA lift kit and a set of 33"X12.50" Pro comp Mud Terrain tires.  I soon realized the vehicle was under powered due to gears in the differentials.  So i geared the front and rear both to 4.57, and now i am hearing a lot of noise in the front while in four wheel drive only.  I am trying to figure out what is causing all this noise and my assumptions tell me it is either the front drive shaft being about a half inch to short and/or has too much of an angle form the lift.  The problem could also maybe be the transfer case is not geared properly.  Has anyone been through this before and can you offer me any advice please?
 
Specifics of problem:
 When in 4 wheel drive going about 30 MPH or more while decelerating the sound is the loudest.  The sound is a notchie ALMOST grinding vibration that can be heard  from the mid to front of vehicle.  If you have any ideas about my situation please contact me as i am in dire needs of resolution.   

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Offline mrfuelish

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Re: Samurai Transfer case, drive-shaft, differential gearing help
« Reply #1 on: October 06, 2012, 01:48:48 PM »
it's something they just do, I drive in two wheel drive on ice because of that, you could cut and roll the knuckles  and point the diff upward to match the transfer case angle but it would look funny to most but you have to have the same angle at each end of the drive line,they have tried cv joints and all from front axles and they still made noise.
1987,1988,1988,1990 samurai's,  1953 m38a1,  1996 x-90,blue.1996 x-90 red.1994 2 door tracker.   only Dead Fish go with the flow.                No Hairy Nosed Wombats were ran over on the trail today.       My ZUK is Xenophobic.

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Offline Merlin93

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Re: Samurai Transfer case, drive-shaft, differential gearing help
« Reply #2 on: October 06, 2012, 03:23:14 PM »
Some possible causes to eliminate (thoughts/ideas, not a diagnosis): 
U-joint binding. 
Front driveshaft hitting cross-member. 
Front output shaft (T-case) slipping (there's a newer version with more engagement, and it's easy to replace.)
Improperly set front pinion/ring gear engagement. 

Your 4.57 R&P gears are a good match for your 33s.  With your early 5th OD gear, you can still add a set oif 4.16:1 T-case gears and be pretty close on the highway. 

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Offline Drone637

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Re: Samurai Transfer case, drive-shaft, differential gearing help
« Reply #3 on: October 07, 2012, 12:20:43 PM »
You shouldn't be in 4wd while driving down the road at high speeds unless you are on a very low traction surface, like snow or possibly gravel.  I think the official recommendation is 25 mph or less.  Found this on ack's faq:

http://www.4x4abc.com/4WD101/def_turnpart.html
« Last Edit: October 07, 2012, 12:23:11 PM by Drone637 »
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Offline Jonny Rash

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Re: Samurai Transfer case, drive-shaft, differential gearing help
« Reply #4 on: October 08, 2012, 09:32:58 AM »
The front driveshaft grinding/vibrating is common with the Calmini SR and is the main reason why I removed my kit nearly 15 years ago.

I also have several stock to mildly lifted Samurais that I use during snow/ice road conditions and they do sometimes see 45mph or so road speeds along the highway.  I have never had any of the front driveshaft issues that I had with the Calmini SR. 

As far as turning, yes on very sharp turns with too much traction (ie turning 90 degrees into a slushy parking spot), you can feel the drivetrain binding up.  I've never had any issues with anything breaking or what not.  All the stress is relieved when you back it out etc.
25+ years of Samurai ownership!