Samurai Transfer Case Gear Install

7 remove 3 mounting nuts securing gear box to. This will permit lever to be removed from gear box. We went to zuks off road in camp verde arizona to see suzuki guru myron thorson install s4 upgrades on a samurai transfer case.

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Rebuilt 6 5 1 tcase 945 rebuilt 6 5 1 tcase large bolt pattern 1099 rebuilt 4 90 1 tcase 799 rebuilt 4 90 1 tcase large bolt pattern 950 rebuilt 4 16 1 tcase 699 rebuilt 4 16 1 tcase large bolt pattern 850 click for pricing.

Samurai transfer case gear install. 6 disconnect 4wd switch lead wire at coupler. Chassis and take down gear box. Universal joint yoke flanges. Low range off road has the largest selection of transfer case gears and parts for your suzuki samurai.

Transfer case oil should be replaced after 1 000 miles then at every 30 000 miles thereafter. Replace your older gear now and keep it in your tool box as a trail spare. Only the front output cover needs to be removed to install this gear. Suzuki samurai 6 5 transfer case gear kit 105004 3 kit suggested tools.

In this video i show ya ll how to shim and rebuild the transfer case on the suzuki samurai. 88 5 samurai with 6 5 1 tcase gears and a harley carb idling in 1st gear low range. So think about this for a minute you put on larger tires so your pinion now becomes twice as hard to turn putting twice as much stress on the u joints transfer case mounts and the transfer case itself. 3 twist control lever guide counterclockwise while pushing it down.

If it is 4 9 4 16 5 14 6 5 or 8 1 gears we have what it takes to not only make your samurai crawl but also rebuild. Samurai complete transfer case installation gears. Complete rebuild we install gears new bearings gaskets seals. The front output gear can be installed without full disassembly of the transfer case.

Conventional or synthetic oil may be used. Hardcore drivers who push the limits of their samurais should know. Fits 1986 1995 suzuki samurai s. While doing suzuki samurai transfer case gears is probably the biggest bang for the buck and a quick fix it is definitely a lousy way to try and create a reliable trouble free drivetrain.

After installing transfer case use the rear fill plug and fill transfer case with 80 90w gl5 gear oil. Reference material used for transfer case rebuild. Ratchet 12mm 14mm and 28mm sockets air wrench needle nose pliers hammer grinder 3 16 diameter pin punch snap ring pliers 6mm allen wrench gasket scraper flat blade screwdriver adjustable wrench permatex ultra grey silicon axle grease if you have questions about installing your gears please call us at 559 252. Once oil starts leaking out of the fill hole the transfer case case is full.