I recently bought an 86 Samurai and I've discovered a problem with it.  it has a spring over axle lift, the rear wheels are locked  and the problem I'm having is there are three 10MM bolts that hold the transfer case to the chassis and two of them keep breaking.  This causes the axle to slam against the transfer case mount (I think that's what it is). 

If anyone knows what I'm talking about, how to fix it or where I can find that information, I'd be most grateful if you helped me out!!! 

I recently bought an 86 Samurai and I've discovered a problem with it.  it has a spring over axle lift, the rear wheels are locked  and the problem I'm having is there are three 10MM bolts that hold the transfer case to the chassis and two of them keep breaking.  This causes the axle to slam against the transfer case mount (I think that's what it is). 

If anyone knows what I'm talking about, how to fix it or where I can find that information, I'd be most grateful if you helped me out!!! 

I think some more info is needed here or better yet pic's. if your AXLE is hitting your t-case mount you have PROBLEMS!!!! 

the only thing I can think of is your driveline is too long and bottoming out causing the bolts to break, there are lots of t-case cradles out there

http://www.lowrangeoffroad.com/suzuki/samurai/transfer-case.html?p=2     start here

First off, thanks for your response.  Ignore me saying the axle was hitting the t case mount, it's the drive shaft (spent too long driving old Volkswagens). 

Okay, the first photo shows the front drive shaft and the support bar/cradle (not 100% sure what it's called).  When moving the Transfer case will rock and the drives haft hits that support bar/cradle. 

The second pic shows the transfer case where it is mounted to the T case mount.  There appear to be 3 bolts that hold it on and the top two have broken.  This allows the transfer case to rock when the vehicle moves and knocks the drive shaft into the support bar/cradle. 

You mentioned my driveline might be too long. How can I determine if that's the case?  There are aluminum spacers between the axles and the drive shaft.  and they appear to be 2" thick, although I did't measure them (I'll do that next time I'm out).

Again, I appreciate your help!

Are you running aftermarket gears in the transfer case?  If so it is common for the stock t-case mounts to tear in two.

My favorite replacements so far are from a Polaris engine mounts:

http://www.zukiworld.com/forum/build-diaries-how-to-diy/sami-polaris-t-case-mounts/

I use a set of 'Bulletproof' t-case mounts with fender washers on them to stop them from pulling through.  They are just some poly-urethane bushings and a bolt so you have a single piece mount.

Others have used the aluminum spacers, but it tends to make any noise in your drive train echo through the entire rig due to everything being metal on metal.  I prefer some sort of bushing to be involved myself.

Or you might look at a cradle system, as Jluck said.  The 'snatch' from Zuk's Off Road or Low Ranges version of it a great options and still allow you to easily remove the t-case.  But any of the T-Case's will work.

Make sure the 4 bolts holding the side of your t-case in place are all tight and have lock-tight on them.  The ones on the passenger side like to work loose, then you can break your t-case in two.

I had the same problem a couple years ago with the rubber mounts breaking on the passenger side and after a looooong day trying to make it home by tying it in place with rope and putting along I made it. This won't happen again as I took some steel tubing that measured about 11/8" o.d. and made solid mounting pads and not a problem since.   Mike