Well, I just took the plunge, and started installing the S/R kit from AAP.

First, you start with a 2wheel drive zuk:

http://www.explorerforum.com/tdavis/zuk/zuk-1.jpg

Next, you rip out that pesky psuedo front axle:

http://www.explorerforum.com/tdavis/zuk/front-axle-1.jpg

and do this:

http://www.explorerforum.com/tdavis/zuk/front-axle-2.jpg
http://www.explorerforum.com/tdavis/zuk/front-axle-3.jpg
http://www.explorerforum.com/tdavis/zuk/front-axle-4.jpg

Nothing's finished on the front yet - this is the first test fit, to see if I've got it right.

you fucker got toy axles I'm jelious :flipoff2:

not just toy axles..

already built toy axles. :D

5.29 gears, full detroit in the rear, ARB in the front. :D

dood that is one clean sami!! I am so jealous!.. did you fab that up yer self.. sure doesnt look like a kit to me!

This is the AAPofAZ YJ S/R kit (http://www.asianautopartsofaz.com/suzuki/suspension.html) I'm using.

Yea, that thing *flew* apart. No stuck bolts, no rusted crap. Easiest vehicle I've taken apart. I moved out here from Nebraska with a Mazda Navajo, and that thing was rusted together..

The zuk sat in a garage in Marin for several years, and then was lived in San Francisco a few more.. Now I've got my grubby hands on it.

This zuk does have love dimples and dents - someone partied on the hood, and it has a broken windshield too.

Originally posted by somone21
you fucker got toy axles I'm jelious :flipoff2:



welll i got toy width d44 :rasta: :rasta:


dan :massey:





:flipoff2: :flipoff2: :flipoff2: :flipoff2: :flipoff2:

yea, but these toy axles have a warn birfield eliminator kit in them, with d60 hubs.

I know I'm going to bust a u-joint in it..

So, more hacking away at it this afternoon.

http://www.explorerforum.com/tdavis/zuk/front-axle-5.jpg

http://www.explorerforum.com/tdavis/zuk/front-axle-6.jpg

http://www.explorerforum.com/tdavis/zuk/front-axle-7.jpg

Yea, that OTT high steer is kind nice. looks like it almost clear. I'll probably have to hack more on that driver side bumper extensions to get the ps box farther forward.

where are you gonna get spares for the warn kit?

Came with spares. One short stub, and one long. Missing the short side (passenger side)

My understanding is they still make the axles, and warrant them.

Man that is one sweet setup! :beer: I'm still a newb and I have no experience with a S/R kit, but your front pinion angle looks like it is going to be really hard on your driveshafts and U joints. I hope I'm wrong but it looks like a recipe for breakage. :nuke:

Ok, I emailed Warn Tech Support about the birf elim kit parts, and it's supported (till May, 2004 they said).

Front pinion angle - yea, that needs to be checked. Part of the problem is the rear isn't up in the air yet - it's still stock.

Wow very clean professional looking job. So many times on the Suzuki BBS's you see guys bragging up what looks to me like hack jobs. I did my own rear YJ swap now I have to make my own front set up. What did you use for shackles? XJ shackles? I seems so weird to see a "dummy" front Zook axle. Every Samurai I've ever seen (& I've seen a LOT) has been 4wd.:eek:

request to see more pictures of the clean Suzuki

You'll just have to wait for pics grasshoppers..

There's still the rear end to do.

what's the thickness on those frame extensions? looks like 1/8" ?
is that strong enough or should I use 3/16" on mine??, I'm gonna make it myself and run some 2x4" box across the front for a stubby bumper.

The stock frame is only 1/8-inch. I used 1/4" which is overkill. 3/16-inch should be perfect. Just make sure whatever you use is welded properly and hopefully gusseted.

More pics:

http://www.explorerforum.com/tdavis/zuk/rear-axle-1.jpg

rear needs the brake line hooked up, perches welded, pinion angle set, e-brake setup. still lots of work on the front.

go here (http://www.explorerforum.com/tdavis/zuk) for more pics.

Wow, I think you are hosed on that front end. It looks to me like the shackle is sitting way to low. Perhaps your YJ spring help bring this back into check? I used Toyota springs on mine as they do not need the ladder bar like the Wrangler springs. Otherwise they are about the same width and length. But watch those center pins.

With my install, the front spring mount, and the shackle mount are equally high off the ground. You seem to have the shackle down several inches. The Toyota axle will not tollerate much more then about 2 degrees in angle changes before your driveline or castor angles are beyond usuable limits. In the pictures, you seem to be out on both angles. Hopefully this is just the picture.

Keep us posted.

-Wayne

Ahh, so I've added a few more pics.

The front axle shackle:

http://www.explorerforum.com/tdavis/zuk/front-axle-8.jpg

With the tires aired up, and off the jack stands, it appears to be about just right..

The angle of the pinion:

http://www.explorerforum.com/tdavis/zuk/front-pinion-1.jpg

The front axle u-bolts aren't torqued down yet, the driver side pad also appears to be bent.

what gearbox is that?

Originally posted by tdavis
With the tires aired up, and off the jack stands, it appears to be about just right..

The front axle u-bolts aren't torqued down yet, the driver side pad also appears to be bent.
Holy positive caster, batman! Get that thing all hunkered down, put the weight on the tires, and put the angle finder on top of the steering arm. I'm betting you've got around 10 degrees of caster... Toys seem to like around 6-7, really.

Probably could be fixed with a shim or by shortening the shackle hangers a couple of inches if it turns out to wobble, but it might not. Death wobble is never very predictable.

More than 10 degrees - closer to 13-14; see:

http://www.explorerforum.com/tdavis/zuk/front-axle-9.jpg

Gearbox? the power steering box? It's a toy IFS 4x4 box (probably 86-87 year)

I put my angle finder on my flange this weekend as I did not think 0 degrees was correct. Mine is at about 5 degrees up towards the t-case.

I think those rear hangers are going to have to go. do something along these lines:

http://RZ-Products.COM/WAYNE/UPDATES/update19.html

Not a very good picture of the suspension, but I think you will get the idea.

Good luck, and keep us posted.

-Wayne

Ok, I'm going to probably shim that frontend to get the caster down.

Called jim@inchworm today - the case adapter is in! Woohoo!

Dont forget to put nuts on them tie rod ends.

Looking at that last pic, if you have 13-14 degrees in that direction you are going to have to rotate the angle 20 degrees the other way. That just seems like alot so I am sure there is something else going on. Plus I wouldn't make the measurement on the steering arm, might as well take it on the dashboard...take it at the pinion like the previous picture. Cause that showed 0 degrees which should be just fine. Measure twice cut/weld once, just make sure you measure at the right spot both times.:D

I checked my castor (caster?) anlge last night, and I'm around the 7 degree mark or so.. A little hard to confirm the angle without pulling off the steering arms. I can adjust my angles a bit by changing the length of my shackle.

-Wayne

Originally posted by Lziffle73

Looking at that last pic, if you have 13-14 degrees in that direction you are going to have to rotate the angle 20 degrees the other way.

Wrong.

See http://aligncraft.com/terms/terms.html#FrontCaster for a good caster definition.

It should be reduced; but not as much as you say. I want in the 5-10 range (7 is good). So putting 6 or 8 degree shims in would tilt up the pinion some, drop the positive caster down, and solve that problem.

Also, since I'm going to be running a dual toy transfer case, I don't think pinion angle is going to be a huge problem on this one. (the rear, on the other hand.. *shudder*)

Originally posted by tdavis


Wrong.

See http://aligncraft.com/terms/terms.html#FrontCaster for a good caster definition.

It should be reduced; but not as much as you say. I want in the 5-10 range (7 is good). So putting 6 or 8 degree shims in would tilt up the pinion some, drop the positive caster down, and solve that problem.

Also, since I'm going to be running a dual toy transfer case, I don't think pinion angle is going to be a huge problem on this one. (the rear, on the other hand.. *shudder*)


If you are going with Shims, I suggest you use only steel shims. The only place that I know sells them is Foothill Offroad. (http://www.foothilloffroad.com/fo_products.htm) I have never bought from them, just thought I'd pass it along.

My dual t-case is so far back that I am planning on running a center bearing on the front driveshaft! Yikes. My rear is so short.. Well, like you said.. Shudder.

-Wayne

Roger Brown sells them too... his website is posted all over the Toy forum if you're interested.

Steel ones rock because you can tack 'em to the perches and won't have to worry about them getting spit out at the worst possible moment.

Yea, I *want* the steel ones, just for that - I can tack/weld them on.

I just haven't decided who to get them from yet.

Originally posted by tdavis


Wrong.


Yes I am, I don't know what the hell I was thinking when I wrote that....just pass me a :beer: and I'll remember.

Don't worry - it only took me, oh, about 15 years to figure out the difference between caster and camber (toe in is easy.. I jut think camel toes..)

[QUOTE]Originally posted by tdavis
[B]This is the AAPofAZ YJ S/R kit (http://www.asianautopartsofaz.com/suzuki/suspension.html) I'm using.

How long did it take you to get your kit from that A.H.? Me not like him very much. I would rather deal with some one that gets your stuff to you on time and is great to deal with like Brent from Trail Tough!!!!!

Ooops other than my last post your rig is looking good.

Originally posted by FLEXYSAMMY
[QUOTE]Originally posted by tdavis
[B]This is the AAPofAZ YJ S/R kit (http://www.asianautopartsofaz.com/suzuki/suspension.html) I'm using.

How long did it take you to get your kit from that A.H.? Me not like him very much. I would rather deal with some one that gets your stuff to you on time and is great to deal with like Brent from Trail Tough!!!!!

I'll PM ya on it. It did take some time..