I searched and did not find any great info on a tear down and rebuild for an 86 samurai transfercase

Is there a how to manual somewhere..

Who is a source of a quality rebuild kit..and can an experienced DIY handle it?

driveline.com lists a kit for 79.00 with bearings and seals..is this a cheap quality kit?

Thanks for your time

I dunno aout the price but Iwould make sure the kit came with USA or Japan made bearings. I just haven't had good luck with the cheap bearings.

I would classify this as a moderate level since you need a press and a bearing Knife.

You can pull up the FSM, page 143 starts the Transfer case.
http://wewt.net/cars/88samurai/fsm/samurai%201988%202%20of%203.pdf



Also here is a lower gear install which will be helpful as well:
http://www.trail-gear.com/tech/zuk65gears/index.html

Sean at Low Range should be able to get you a rebuild kit:
http://www.lowrangeoffroad.com/samdrivetrain.htm

or Scott at rock4xfabrication can get it for you:
http://www.rock4xfabrication.com/store/product_info.php?cPath=21_39&products_id=86

You can't go wrong with either one of these guys. Both have excellent customer service in my opinion.

Might want to ask about ordering the the needle bearings as well, as I see neither of their kits has them in it.

Trail Gear has step by step instructions on their site. Just print them out.

thanks a bunch guys ..

I sure appreciate the help

regards

Morgan

Trail Gear has step by step instructions on their site. Just print them out.I was going to say the same my haynes doesn't have a rebuild section for the t-case. Just use Trail Gear's instructions and minus the grinding of the case:laughing:
http://www.trail-gear.com/tech/zuk65gears/index.html

Does anyone ever read the post, ALL the way through? :D

Hi, I built my own rocklobster using http://www.suzukiclubuk.com/rocklobster.html

Take out old bearings n seals, took em to a bearing supplier to match n supply new uns, cost £50.
New gaskets from Suzuki, part numbers 29525-800500 and 29535-80050 (there are 2) only a fiver.
Hope this helps, just dont forget to put them gold shims back in.

Ok, hope someone is available to help me. I am doing a rebuild on my Trans case and used the source located here from trail gear http://www.trail-gear.com/pdf/suzuk-tcase.pdf I am at step 84 and noticed that its asking for a bearing spacer. When I tore my tcase apart there was never a spacer located there. Is this something that came with the Trail Gear kit? I am rebuilding a stock tcase and not using the tcase kit as shown. Please help I hope someone is available....

Thanks !!

Never mind, I found a parts list and yes its needed. This case was rebuilt and seems like the nut head that rebuilt it left the part out.

He may have pulled the shim if he just used RTV silicon. That way no bind, but I would reccomend a proper gasket and the shim. I was working on a TT 6.5:1 gear set today. Pressed all the bearings and collars. This is a pretty easy job, IMO. 10-15 minutes max to press the bearings. I have done 4-5 of them now. If you do get some new gears I would recommend the Trail Tough set. They have proven themselves to be the most reliable.

X2 on the Japanese or USA bearings. The china ones are not worth the savings:shaking:

Thanks, gasket was installed, I believe he just left it out, the tcase looked like some kid put it together with the orange rtv all over it.