This info seems to be very well appreciated on  ZuWharrie, ZukiKrawler and Suzuki Club UK and was moved to sticky’s shortly after posting.  Hope that you get something out of it as well.

The trans is not talked about too much and being in the process of rebuilding the one going in this build. Thought it would be a good time to share a few tips and tools that were picked up on in a couple of pervious rebuilds.

Reference Rebuild Info:

This is a good step by step and pics
http://www.geerdijk.com/files/suzuki/tranny_rebuild.pdf

The FSM will be needed for a few things that were not covered.


This is my minimum parts list and parts # from LROR.

 1----STM-ISR-----------Samurai Transmission Front Input Housing Bearing Retainer
 2----STM-CRSB--------Samurai Clutch Release Shaft (throwout) Bushing
 1----STM-TNB----------Samurai Transmission Needle Bearings
 1----STM-RRTB--------Suzuki Samurai Transmission Tail Shaft Bushing
 1----STM-UTM---------Unbreakable Rear Transmission Mount
 1----SDT-TBS----------Samurai Transmission Shifter Bolt 86-89
 1----STM-TIP-----------Samurai Timing Inspection Plug
 1----SDT-TMBN--------Samurai Nylatron Transmission Shifter Bushing
 1----STM-RKS----------Samurai Transmission Rebuild Kit w/ Syncros And Silicone
 1----STM-CRSOS-----Clutch Release Shaft (Throwout) Oil Seal


There are a few grey areas I will try and shed some light on.

The countershaft installation is one of those grey areas. This is the procedure that works well with a press, mallet, couple of sockets and a piece of pipe.

Pics are marked in detail

Here is another one of those gray areas that I will walk you through.

Rear Tailshaft Bushing is something that is probably overlooked.

A couple of reason for changing it are:

There always seems to be metal shavings on the rear tialshaft bearing location flange. The worn out bushing seems to be causing this problem.

The worn out bushing will also cause the driveshaft to have excess runout and will cause the seal to leak prematurely.

The pics are marked in order of removal and install.

Here is a link to one of the other threads that gets updates and questions

Link


http://www.zukikrawlers.com/showthread.php?t=45336