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02-04-2003, 01:26 PM
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#1 (permalink) | |
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ZUK Herder
Join Date: Mar 2004
Member # 28426
Location: Live free or die
Posts: 2,447
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*FAQ* The Official PBB Suzuki BIBLE-updated JUL 26 2012
FAQ TOPICS General Suzuki Informaion Models/Types AXLE INFO INCLUDING SWAPS AISIN HUB INFO hub interchangeability /forum/suzuki/884089-aisin-locking-hub-tech-interchangeability-converting-samurai-lockouts-toyota.html http://www.pirate4x4.com/forum/showt...highlight=hubs STOCK ZUK AXLE INFO Killer 300M axleshafts Zook 27spline axles and spool upgrade? Dilemma: D44 vs. yota TT Double Tough shafts =1, Grade 12.9 hub bolts = 0 newfield thread http://www.pirate4x4.com/forum/showt...807&highlight= Lunch box locker tech /forum/suzuki/766629-faq-zuk-lunchbox-locker-tech.html Sidekick & Tracker Axles -General Information -What Gears can use on a Samurai DANA AXLE SWAP INFO http://www.pirate4x4.com/forum/showt...hreadid=120802 -Gears -Steering -Swap Information -Links TOY AXLE IN ZUK INFO http://www.pirate4x4.com/forum/showt...hreadid=116013 -Gears -Steering -Swap Information -Links fitting 30 spline longfields in toys http://www.pirate4x4.com/forum/showt...ight=longfield toy FAQ /forum/toyota-truck-4runner/459180-official-pbb-toyota-faq-last-rev-11-2007-a.html shaved trussed and armored axle collection (from toy forum) http://www.pirate4x4.com/forum/showt...ghlight=shaved Toyota Front Axle Information & Specifications FJ AXLE IN ZUK INFO /forum/suzuki/201955-faq-toyota-land-cruiser-fj60-axles-into-samurai.html -Gears -Steering -Swap Information -Links General Axle Swap Discussion http://www.pirate4x4.com/forum/showt...threadid=68952 http://www.pirate4x4.com/forum/showt...threadid=22276 (note maybe later we can summarize those threads here...pro/cons etc...) -Electrical T-CASE/TRANNY INFO Samurai – How to set up a transfer case for 2WD-Low Shifter Q. Shifter problems/can't put it IN a gear or remove it from a gear. A. Start with the shifter sheet. To remove it push down on retaining ring and turn CCW. Then pull shifter up/out. See vender list for new sheets, ALL VENDORS HAVE NEW SHIFT SHEETS Front output pilot bearing removal /forum/suzuki/783322-front-output-pilot-bearing-removal.html Volvo AW71 Transmission install 1.6 Tranny/Tcase Gear reduction Stuff http://www.ottindustries.com and various track/kick adapters and reduction kits.... INCLUDING KICKER3 If your in the US, call someone like jim@inchwormgear.com (http://www.inchwormgear.com), they will deal all the customs stuff and getting a hold of OTT. -Gearing Thoughts/Concepts.. Q. Which is better axle gearing or a t-case kit ? A. While doing transfer case gears is probably the biggest bank for buck and a quick-fix, it is definitely a lousy way to try and create a reliable, trouble-free drive-train. Think about this for a minute... You put on larger tires. Now your pinion becomes TWICE as hard to turn. This puts TWICE as much stress on the u-joints, the transfer case mounts, the transfer case itself, and the brackets on the side of the frame that holds the transfer case in place. "GEE I wonder why I need these big honkin' driveshafts now"...or "why do my bolts pull out of the transfer case on the long arm side"... or the mounting boss breaks off of the transfer case....or the short arm side bracket starts tearing off of the frame rail. "Gosh - maybe it is because I gave my transfer case almost 3 times as much power by putting in 6:1's and now it wants to do flip flops in its mounts because I must have FORGOT to change the ring and pinions relative to my tire size - which would have made the drive-shaft easy to turn again and takes all of the strain off of these parts - like it was made from the factory when the little tires were on it." It is a MISTAKE to do all of your gear reduction at one point. Especially that far up the mechanical chain. Do yourself a favor...reduce the ratio at the ring and pinions relative to the size tire you want to run, then select the transfer case gears that will best meet your 4-wheeling needs. By going this route, you will have a well thought out and trouble-free drivetrain working well within the parameters of strain that the parts can and will reliably handle. -Brent (Trail Tough Products) T CASE REBUILDS http://www.izook.com/tech/samurai/dr...rs2/pwgrs2.htm http://www.trail-gear.com/tech/zuk65gears/index.html TWIN STICK TECH http://www.pirate4x4.com/forum/showt...ght=twin+stick http://www.pirate4x4.com/forum/showt...ght=twin+stick http://www.pirate4x4.com/forum/showt...ght=twin+stick http://xfaktor.net:8082/Projects/Suz...html#TwinStick Suzuki Drive-shafts Samurai driveshaft length info Lengthening drive shaft how to /forum/suzuki/872959-lengthening-drive-shaft.html Doubler FAQ /forum/suzuki/734171-zuk-doubler-faq-please-help-build-faq.html /forum/suzuki/958201-so-another-home-made-tracker-range-box.html Suzuki/Geo Doublers are here! (Sidekick to Dana 300) ZUK ENGINES Engine Engine Swap Bellhousings Suzuki 1.6L Engine Swap MSD ignition install writeup 1.3 Engine G series specs database Suzuki G Series Engines - Wikipedia List of Suzuki Engines - Wikipedia -Pullys Q. What pullies can I swap on? A. Chevy Sprint 1.0L is a great swap, has stock water pump pully AND an overdrive for power steering, and other accessiries. The 1.0L is also made by suzuki, so other vehicles with this or similer engines should work.... Acks 1.6 16v wiring Cylinder Head Tech: writeup on suzuki 8V cylinder heads and crankshafts, differences/similarities, and planimetric schematic of combustion chambers for determining how much to mill for desired compression ratio: http://pirate4x4.com/forum/showthread.php?t=639274 (more engine tech to be added eventually) Ignition Tech: wiring an MSD ignition box into your samruai with separate diagrams for common combinations of computer control hitachi or TBI, carbs/propane, factory tach or aftermarket tach: http://pirate4x4.com/forum/showthread.php?t=721133 ZUK CARB INFO http://www.pirate4x4.com/forum/showt...i+carb+rebuild VACUUM -Alternator Upgrades 1.6 L Engine link to team swifts 1.6 forum (need to build a better 1.6 FAQ) http://www.teamswift.net/viewforum.php?f=7 1.6 wiring FAQ /forum/suzuki/765610-faq-wiring-8v-1-6-a.html PROPANE INFO PROPANE INFO -1.3 TURBO 1.3 TURBO INFO -16 VALVE PROPANE 16 VALVE PROPANE INFO 2.0 info Vitara Engine Tech - two liter 2.0 Liter tach fix 2.0 swap in first gen track/kick 22r swap http://www.zukikrawlers.com/showthread.php?t=28 other 4 bangers ecotec conversions 4.3 BRAKES ZUK rear disks with nissan calipers and Firebird master Master cylinder help Mazda 929 Brake Master Cylinder Upgrade - BOLT ON! Subaru master cylinder how to Shuduck's Subaru master cylinder how to Transfer Case Emergency Brake STEERING INFO biggest setup without power steering? Full Hydro info: /forum/suzuki/793350-zuk-full-hydro-cheap.html /forum/suzuki/888735-full-hydro-budget.html Full Hydraulic Steering from Performance Off-Road Systems By BillaVista Hydro assist: Toyota hydro assist tech (courtesy of the Toyota FAQ) Toyota power steering and ram hose diagram Power Steering: Toyota truck power steering pump bracket to 1.3 Samurai What are you running for steering?? Howe power steering bleeding instructions suspension Spring Length Chart post up your 4 link lengths with some pics linky linky every where (aka what rod ends do you run) Link suspensions for dummies? THE GOD OF SUSPENSION...[for those of you who don't know] Suspension geometry for GETIN IT! General Weight list: engine, axles, t cases, etc. IF ITS NOT IN THIS FAQ THEN YOU CAN FIND IT ONE OF THESE: ACKS FAQ http://www.acksfaq.com IZOOK: http://www.izook.com/tech/ Suzukiinfo.Com: http://www.suzukiinfo.com OTHER FAQ's PBB ZUK BUILD TABLE OF CONTENTS Toyota FAQ Chevy TOTW's Ford TOTW's Isuzu FAQ Mercedes FAQ The Official Pirate4x4.com Jeep Talk Bible Triaged's 4-link Analyzer / Calculator Vendors SUPORT THOSE THAT SUPORT THE BOARD! http://www.pirate4x4.com/forum/vendors.php ZUK vendor list: (listed in no order, preference; Some do not support PBB) If you have a question about a product bug these guys, not the PBB (unless you bought something, and reviewing it for us). www.ShrockWorks.com www.spidertrax.com www.trailtough.com www.lowrangeoffroad.com www.hawksuzukiparts.com/ www.roadlessgear.com www.puresuzuki.com/suzukimain.htm (Calmini) www.petroworks.com www.rocky-road.com www.rock4xfabrication.com www.asianautopartsofaz.com/ www.wheelersoffroad.com www.davesport.com http://www.ottindustries.com www.datinfab.com www.calmini.com PRODUCT REVIEW THREADS http://www.pirate4x4.com/forum/showt...85#post8905485 Sites Worthy of Mention http://www.azrockcrawler.com www.bc4x4.com SAMURAI WIKI izook ITEMS THAT NEED FAQS if anyone has one PM your MOD General Steering Stuff Stock Steering Power Steering Spring Swaps CJ spring swap FAQ YJ spring swap FAQ SEARCH TIPS Search feature for three letter words Search leaves out three letter words. If you want to search for IFS (or any other three letter or number combination), use an asterisk (*) like this: IFS* or *IFS. The search will use that as a wildcard. USING GOOGLE TO SEARCH If you DON'T have a red star you can not use the the search feature - you can either pay the $20/yr http://www.pirate4x4.com/forum/payments.php or use just use Google Advanced Search. Just put "www.pirate4x4.com" into the domain search field along with what you are looking for. For example to find info on 2.0 motor swaps, type into the google search field - "site: pirate4x4.com 2.0 motor swap". Quote:
Last edited by supazuk94; 07-26-2012 at 08:43 AM. |
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02-09-2003, 08:10 PM
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#2 (permalink) |
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Registered User
Join Date: May 2002
Member # 11628
Location: Ann Arbor Mi.
Posts: 1,455
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Add this link to the list:Lincoln (Fozzy) Locker
There is tech at bc4x4, but its gotten burried, I'll dig it up for this. Last edited by supazuk94; 10-24-2008 at 10:00 PM. |
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02-11-2003, 01:51 PM
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#3 (permalink) | |
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Registered User
Join Date: Dec 2001
Member # 8687
Location: Vancouver Island B.C.
Posts: 1,083
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There's some stuff here.
 http://www.angelfire.com/ns2/por-tech/POR_TECH.htm Quote:
Last edited by supazuk94; 04-24-2011 at 09:38 AM. Reason: added text from page in case site is lost |
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02-13-2003, 12:49 PM
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#4 (permalink) | |
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Registered User
Join Date: Dec 2001
Member # 8601
Location: ON, Canada
Posts: 947
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Brief Samurai/SJ-413/SJ-410 Chronology - what to llok for when buying a SJ Suzuki
Taken from here: Old Thread
Quote:
Last edited by Root Moose; 02-13-2003 at 12:52 PM. |
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02-14-2003, 11:38 AM
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#5 (permalink) |
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Registered User
Join Date: Dec 2001
Member # 8601
Location: ON, Canada
Posts: 947
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410 vs 413 vs Sam axles
Since someone asked, I'll break it out from the above.
Interchanges: 413 to Sam - diff assemblies. 413 LWBs had 3.90 ratio. Sam is 3.73 ratio. No axle shafts interchange between 410/413/Sam. 413/Sam are ~2" different in length per side. 410 and Sam are completely different. I am like 75% sure that 410 and 413 shafts will not interchange (correct me if I'm wrong). They are the same length though, different spline count. 410 to 413 - Some early 413s have 410 brakes. Diff assemblies are NOT interchangable. 410 to LJ-80 (50?) the diffs are interchangable, LJ-80 is 4.56:1, 410 is 4.1:1. Shafts do NOT interchange. Common upgrade is SJ-410 front brakes to replace LJ-80 front drums. Bolt on assembly. Common 410 upgrade is 413 axles outright. Common 413 upgrade is Sam axles outright. When doing spoa makes for a little involved front passenger side perch as the perch rides the diff a little. I'm probably forgetting a few minor points. I'll update the thread if they occur to me. HTH |
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02-18-2003, 08:48 PM
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#6 (permalink) |
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Registered User
Join Date: Oct 2002
Member # 14194
Location: BC
Posts: 105
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Moose. Jus so others don't get confused ------ 413------- you are referring to an 1985 model year only. Is this right?
I am like 75% sure that 410 and 413 shafts will not interchange (correct me if I'm wrong). They are the same length though, different spline count. Can anyone verify the above about interchanging 410 and 413 shafts.
__________________
Number 22 off the line. 1983 SJ410- still going. Last edited by whats his name; 02-18-2003 at 08:52 PM. |
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02-19-2003, 05:10 AM
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#7 (permalink) | |
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Registered User
Join Date: Dec 2001
Member # 8601
Location: ON, Canada
Posts: 947
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Quote:
r@m |
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03-14-2003, 02:45 AM
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#8 (permalink) |
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Registered User
Join Date: Jun 2002
Member # 12382
Location: hamilton in
Posts: 327
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addition
ive got a sam prod date nov-85............
things so far that are different than my 88 are.......... d/l slip joint has a smaller spline size.......... flange yolks {d/l and axel} are smaller................. but i had an axel bearing go away on my 88 {long side} and the long side {axel shaft} appears to be the same length or at least i put it in my 88 and am driveing it back and forth to work everyday.................. i havent checked the gear ratio {axel} of the 85 just yet..... is it possible that the nov/85 prod date would make this thing some sort production crossover mix of a 413 and a samurai... Last edited by supazuk94; 10-24-2008 at 09:58 PM. |
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04-02-2003, 06:48 AM
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#9 (permalink) |
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Registered User
Join Date: May 2002
Member # 11628
Location: Ann Arbor Mi.
Posts: 1,455
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WMS Dimensions
Axle Wheel Mounting Surface (WMS)
Samurai: Rear = 52.2" WMS to WMS Front = 52.5" WMS to WMS These measurements were taken from Stock 1986 Samurai axles. Measurments may differ slightly due to build variation and parts sourcing. Last edited by supazuk94; 10-24-2008 at 09:58 PM. |
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04-22-2003, 11:18 AM
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#10 (permalink) |
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Evil Twin
Join Date: Mar 2002
Member # 10695
Location: Raleigh, NC
Posts: 2,876
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Manufacturing Tolerances 101
Tolerancing 101: by Orionn (mark)
In short: The system of catagorizing the min/max tollereances into "A,B,C" sizing was developed to reduce the amount of mathmatics needed by the assembler to properly assemble these two parts. In the manufaturing of all the individual pieces, the equipment used to produce all the parts, that is all of the Dies, cutters and mills, have set tollerances in which they are set up to and 'run' in as well. There is ALWAYS a size difference in cylinder bores, pistons, and such on any Production engine, or for that matter, ANYTHING that is made, be it by machine,or hand. Its inevitable. that being said, all the parts made will also have tollerances themselve. these 'manufacturing tolerances' are the range of minimum and maximum sizes allowed to produce a 'good' part. (Remember, that all tooling wears with use and age. And no two machines/tools wear or age the same. This affects how a part made with that tooling will measure out against the tollerances set up for that part. Thats the reason for the min/max dimensions on blue prints). knowing that no two parts are exactly the same, certain features of the part are determined to be 'key' for the overall function of the part. In this case, its engine block bore and piston diameter, After the individual part is produced, the key features are measured on that part, and then the measurments compaired to a chart to give it its proper designation of 'A', 'B', or 'C'. The OEM manufacturers take an even more detailed approach to tollerancing for assembly, in that each bore in a block is labled with a letter denoting a certain size, or tolereance. Then an appropriate mating piston is selcted for each individual cylender. In that way you cannot put a 'A' piston inside a 'C' bore on the engine block. this prevents situations of too tight of pistons or too loose of a piston, both of which can generate problems such as piston slap, lost compresion, siezure, thrown rods and the like. (this is what has given Ray a block with all different bores/piston combinations) From a Rebuilding standpoint, the A,B,C method is ALOT less noticable, but still evident. A good rebuilder will first measure the pistons (new or used) to determine the sizes of the individual parts, then bore and hone each cylinder with proper clearances for the piston asseblies, on an individual basis. (this is done more when using 'used' parts than 'new'). When new pistons are purchased, they are purchased pre-sorted to different sizes: stock, .010, .020, .030, ect. over bore. To arrive at this point, the manufacuterer of the piston will cast/ forge in a certain toleranced die, do the final machining for size, then sort each 'size' by a tolerance range into 'sets' to be sold. Becouse of this, 'pre-tolerancing' of the piston sets, the machine shop has a much easier time boring a block for the new piston set, as they will all be of a simular size(within a predetermined tolerance for that set). This whole process of tollerancing and re-tolerancing of parts goes on through the entire process of manufacturing and assembly untill you have a complete engine, ready to run. this is a VERY basic example of how tollerancing CAN work, it is not an indepth explination, there are people in all areas of manufacturing that have made this thier only job, to set up tollerances for parts. I am NOT one of those people, but work with them enough for a rudementry explination of a few of the concepts that go into the process. I hope that this all makes sence, I have left out ALOT of information that would cofuse the issue easily. so if you have questions, ask me, i will try to clarify what I can for you. mark Last edited by supazuk94; 10-24-2008 at 09:57 PM. |
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07-11-2003, 10:14 AM
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#13 (permalink) |
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Hillbilly Houndsman
Join Date: Aug 2002
Member # 13420
Location: Kenna, West Virginia
Posts: 6,819
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BRAKE LINE (longer than stock)
This is a summary of other posts. http://www.pirate4x4.com/forum/showt...rake+and+lines Rockrat: Brake lines… Sami Front -->mid 90's Tracker front RIGHT(21 1/2")pn# ?, or an 83 honda Accord FRONT either side(20")napa# 38673 Sami Rear --> front brake hose for a 90-96 Nissan 300ZX(23 3/8")NAPA part #38688 ghost dog: Geo Metro's also work. Good pocketparts. dumb: Subaru brake lines also fit and are really fricken long! I don't know what the part number would be for new, but they are pretty easy to find in my neck of the woods at the pnp. spencurai: I used the front brake lines from a solid axle toy pickup for my rears on my zuk and the tracker lines for the front. Last edited by supazuk94; 10-24-2008 at 09:56 PM. |
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02-05-2004, 07:02 PM
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#14 (permalink) |
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Registered User
Join Date: May 2002
Member # 11628
Location: Ann Arbor Mi.
Posts: 1,455
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Basic Exterior dimensions, SWB
Exterior Dimensions, SWB Samurai (SJ413):
Wheelbase 79.9 in. (2030 mm) Tread width: Front 51.2 in. (1300 mm) Rear 51.6 in. (1310 mm) Overall Length: 135.0 in. (3430 mm) Overall Width: (Body) 60.2 in. (1530 mm) Overall Height: 65.6 in. (1665 mm) Minimum ground clearance: 8.1 in. (205 mm) Curb Weight: Manual 2094 lb. (942 kg) Gross Vehicle Wt. Rating: 2923 lb. (1315 kg) Gross Axle Wt. Rating: Front 1257 lb. (566 kg) Rear 1675 lb. (754 kg) I barrowed this from here: Off-Road.com Last edited by supazuk94; 10-24-2008 at 09:55 PM. |
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06-03-2004, 06:41 AM
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#16 (permalink) | |
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Registered User
Join Date: May 2002
Member # 11628
Location: Ann Arbor Mi.
Posts: 1,455
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Wheel bearing part number and other info:
Taken from a previous post by AkDale:
Quote:
Last edited by supazuk94; 10-24-2008 at 09:53 PM. |
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07-12-2004, 09:14 PM
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#17 (permalink) |
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Registered User
Join Date: Dec 2002
Member # 15343
Location: PARADISE GUAM, USA 13N/144E
Posts: 2,616
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1.6 16valve swap
from the donor vehicle get the following......
You will need the engine complete with all of the hoses, pulleys intact. You will need the fan, starter, alternator, coil, air cleaner, exhaust manifold, head pipe, engine room wiring harness, under dash wiring harness, ECM, and speedometer. In addition to this donor parts list you will also need a high pressure fuel pump, an engine adaptor kit, and slightly taller mounts or shims for the front 4 body mounts in order to provide for hood clearance. The donor vehicles wiring harness will need to be modified for use in the Samurai as well as the Samurai speedometer which will need the speed sensor from the donor vehicle adapted to it. __________________ Last edited by supazuk94; 10-24-2008 at 09:53 PM. |
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07-14-2004, 05:44 AM
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#18 (permalink) |
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Registered User
Join Date: Dec 2002
Member # 15343
Location: PARADISE GUAM, USA 13N/144E
Posts: 2,616
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some specs
Ignition System Spark Plugs ____Type ________1990 and earlier.................................... NGK BPR-5ES ________1991 and later...................................... NGK BKR-6E ____Gap........................................... ................ 0.7mm to 0.8mm (0.028 to 0.031 inches) Timing ____Samurai....................................... .............. 10 degrees BTDC @ 800 RPM ____Sidekick/Tracker.......................................... 8 degrees BTDC @ 800 RPM Firing Order............................................. .......... 1-3-4-2 Cylinder Numbers (drivebelt end first)..................... 1-2-3-4 Valve Clearances 8-valve ____Intake _______Cold....................................... ................ 0.13 to 0.17mm (0.005 to 0.007 inch) _______Hot........................................ ................ 0.23 to 0.27mm (0.009 to 0.011 inch) ____Exhaust _______Cold....................................... ................ 0.016 to 0.20mm (0.006 to 0.008 inch) _______Hot........................................ ................ 0.26 to 0.30mm (0.010 to 0.012 inch) ____16-valve (intake and exhaust) _______Cold....................................... ................ 0.13 to 0.17mm ( 0.005 to 0.007 inch) _______Hot........................................ ................ 0.17 to 0.21mm (0.007 to 0.008 inch) Back to Top Compression Cylinder compression @ 400 RPM ____Standard...................................... ................____199 psi ____Minimum....................................... ................____170 psi Maximum variation between cylinders.......................____14.2 psi Oil pressure (warm) ..............................................____ 42 to 60 psi @ 3000 RPM Cylinder Head Warpage limit............................................. .........____0.05mm (0.002 inch) Drivebelt Deflection Alternator .................................................. ........____6mm (0.25 inch) Power steering pump ...........................................____12. 5mm (0.5 inch) Air conditioning compressor....................................____ 6mm (0.25 inch) Brake Specs Disc brake pad lining thickness (minimum) ................____1mm (0.04 inch) Drum brake shoe lining thickness ............................____1mm (0.04 inch) Parking brake adjustment......................................__ __5 to 8 clicks Brake pedal freeplay.......................................... ...____1 to 8mm (0.04 to 0.32 inch) Brake pedal height ..............................................____ 130mm (5.12 inches) Clutch Clutch pedal Freeplay.......................................... ................... 15 to 25mm (o.6 to 1.0 inch) ____Height ________Samurai ................................................. Level w/ brake pedal ________1990 and earlier....................................... 5.0mm (0.2 in)above brake pedal Clutch release arm freeplay..................................... 0.5 to 1.5mm (0.02 to 0.06 inch) Steering Steering wheel freeplay limit.................................... 10 to 30mm (0.40 to 1.2 inches) Last edited by supazuk94; 10-24-2008 at 09:53 PM. |
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07-14-2004, 05:48 AM
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#19 (permalink) |
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Registered User
Join Date: Dec 2002
Member # 15343
Location: PARADISE GUAM, USA 13N/144E
Posts: 2,616
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torque specs
 Engine____________________________Ft-lbs Spark Plugs............................................. ......_21 Camshaft cover bolts......................................_3 to 3.5 Intake/exhaust manifold nuts/bolts...................._13.5 to 20 Camshaft sprocket bolt..................................._41 to 46 Cylinder head bolts ____8 valve engine........................................_46 to 50 ___16 valve engine _______Step 1.............................................._25 _______Step 2.............................................._40 _______Step 3.............................................._48 to 50 Crankshaft pulley bolts...................................._7.5 to 9 Crankshaft pulley center bolt ____8 valve engine........................................._52 ___16 valve engine........................................._76 to 83 Oil pump gear plate bolts.................................._7 to 8.5 Oil pump-to-block bolts...................................._7 to 8.5 Oil pan bolts/nuts..........................................._7 to 8.5 Flywheel/driveplate bolts.................................._58 Timing belt cover............................................_ 7 to 8.5 Rear main seal housing bolts............................._8 Rocker arm shaft retaining screws......................_7 to 8.5 Timing belt tensioner bolt................................._17.5 to 21.5 Timing belt tensioner nut.................................._7 to 8.5 Engine mounting center member bolt.................._43 Distributor gear case bolts................................_6 to 7.2 Main bearing cap bolts....................................._36.5 to 41 Connecting rod cap nuts.................................._24 to 26.5 Manual Transmission________________Ft-lbs Oil fill and drain plugs......................................._20 Transmission-to-engine bolts/nuts ____Samurai....................................... ..........._16 to 25 ____Sidekick/Tracker......................................._51 to 72 Input shaft bearing retainer bolts......................._14 to 20 Shift lever retainer bolts (Samurai)....................._30 to 60 in-lbs Auto Transmission__________________Ft-lbs Transmission-to-engine bolts and nuts................_62 Torque converter-to-driveplate bolt..................._62 Oil pan bolts............................................. ....._9 Transfer Case______________________Ft-lbs Transfer case-to-transmission nuts....................._20 Shift lever case center bolt..............................._60 in-lbs Shift lever case bolts ____Sidekick...................................... ............_144 in-lbs ____Tracker....................................... ............_20 Samurai Transfer case flange nut........................_80 to 108 lbs Clutch and Drivetrain__________________Ft-lbs Pressure plate-to-flywheel bolts.............................._14 to 20 Driveshaft nuts and bolts ____Samurai....................................... ................._17 to 22 ____Sidekick and Tracker......................................._36 to 43 Freewheeling hub ____Manual locking _______Hub body bolts........................................._15 to 22 _______Hub cover bolts........................................_72 to 109 in-lbs ____Automatic locking _______Hub body bolts........................................._15 to 21 Kingpin bolts (Samurai)......................................... ._15 to 22 Pressure plate-to-flywheel bolts.............................._14 to 20 Front wheel bearing nut (Samurai)..........................._96 to 132 in-lbs Front wheel bearing lock nut (Samurai)....................._43 to 65 Driveaxle flange bolt and nut (Sidekick/Tracker)........._29 to 43 Front axle housing mounting bolts (Sidekick/Tracker) ____Left side.............................................. ........._37 ____Right side.............................................. ........_37 ____Rear.......................................... ..................._37 Front wheel bearing locknut (Sidekick/Tracker) ____1992 and earlier (all models)............................._89 to 148 ____1993 and later _______Tracker.................................... ..............._155 _______Sidekick................................... ................_180 Differential carrier bolts ____Samurai....................................... ................._20 ____Sidekick/Tracker........................................... .._41 Differential drain plugs ____Front......................................... ..................._32 ____Rear.......................................... ..................._36 Brake backing plate bolts/nuts................................._14 to 20 Wheel lug nuts.............................................. ........ Suspension_______________________________Ft-lbs Front Suspension_ Samurai ____Leaf spring U-bolt nuts..........................................._44 to 58 ____Leaf spring shackle pin nut......................................_22 to 40 ____Leaf spring eye-to-frame bolt.................................._33 to 50 Sidekick and Tracker ____Front strut/shock absorber upper mounting nuts.........._14 to 22 ____Front strut/shock absorber-to-steering knuckle nuts...._58 to 75 ____Lower control arm _______Front nut............................................... .........._50 to 75 _______Rear nut............................................... ..........._65 to 100 ____Balljoint stud nut............................................... ....._32 to 50 ____Balljoint-to-lower arm nuts......................................._50 to 75 ____Spindle-to-steering knuckle bolts..............................._29 to 43 Rear Suspension_ Samurai ____Leaf spring U-bolt nuts............................................_4 4 to 58 ____Leaf spring shackle pin nut......................................._22 to 40 ____Leaf spring eye-to-frame bolt..................................._33 to 50 Sidekick and Tracker ____Rear balljoint boss bolts..........................................._2 9 to 43 ____Upper arm bolts............................................. ........._58 to 72 ____Proportioning stay bolts..........................................._1 7 ____Trailing rod nuts.............................................. ......._58 to 72 Steering__________________________Ft-lbs Steering wheel nut........................................_18 to 28 Steering gear mounting bolts..........................._51 to 65 Intermediate shaft pinch bolt.........................._14 to 22 Pitman arm-to-steering gear nut......................_101 to 129 Tie-rod end ballstud nut................................._22 to 40 Steering shaft rubber joint bolts......................._11 to 18 Pitman arm nut............................................._1 01 to 129 Drag link nut (Samurai)..................................._22 to 50 Center link nut (Sidekick/Tracker)....................._22 to 50 Idler arm nut (Sidekick/Tracker)......................._50 to 72 Steering knuckle seal retainer bolts..................._96 in-lbs Fuel and Exhaust___________________Ft-lbs Fuel pump-to-cylinder head nuts........................_7 to 11.5 Carb/throttle body mounting nuts/bolts..............._13.5 to 20 O2 sensor............................................ .........._40 Cooling____________________________Ft-lbs Fan clutch-to-water pump nuts........................._6 to 8.5 Thermostat housing bolts................................._7 to 12 Water pump-to-block bolts..............................._7 to 9 Brakes____________________________Ft-lbs Brake bleeder screw........................................_8 Brake hose-to-caliper inlet fitting bolt................_14 to 18 Caliper carrier bolts........................................._51 to 72 Caliper mounting bolts....................................._18 to 20 Master cylinder mounting nuts..........................._7 to 12 Power brake booster mounting nuts...................._7 to 12 Wheel cylinder mounting bolts..........................._6 to 9 Body____________________________Ft-lbs Door_ ____Glass stud nut..........................................._4 ____Hinge bolt.............................................. ..._26 ____Handle nut............................................... ._4 ____Latch screw............................................. ._7 Front door vent window screw............................_1 Rear door stationary glass channel frame screw....._1 Hood hinge bolt.............................................. .._23 Lift gate ____Hinge bolt.............................................. ..._7 ____Latch screw............................................. ._7 ____Striker screw............................................. _22 Front seat frame-to-floor nut.............................._18 Rear seat-to-seat back cushion hinge bolt............._33 Safety belt anchor bolt......................................_36 Last edited by supazuk94; 02-04-2009 at 07:54 AM. |
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07-14-2004, 05:49 AM
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#20 (permalink) |
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Registered User
Join Date: Dec 2002
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Location: PARADISE GUAM, USA 13N/144E
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Capacities
 Engine Oil............................................... .............__4.4 litres Cooling system............................................ .........__5 litres Fuel tank.............................................. ...............__40.1 litres Differential lubricant ____Samurai _______Front...................................... .................__2 litres _______Rear....................................... .................__1.5 litres ____Sidekick/Tracker _______Front...................................... .................__1 litre _______Rear....................................... .................__2.1 litres Manual transmission lubricant ____Samurai....................................... .................__1.5 litres ____Sidekick/Tracker........................................... ..__1.8 litres Automatic transmission fluid....................................__2.8 litres Transfer case lubricant ____Samurai....................................... .................__1 litre ____Sidekick/Tracker........................................... ..__2 litres Last edited by supazuk94; 10-24-2008 at 09:54 PM. |
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07-18-2004, 04:52 AM
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#21 (permalink) |
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Registered User
Join Date: Dec 2002
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Location: PARADISE GUAM, USA 13N/144E
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samurai SJ413 transmission ratios...
Manual Transmission Type Five-speed, all synchromesh Clutch Dry, single disc, diaphragm spring Gear ratios 1st 3.652 2nd 1.947 3rd 1.423 4th 1.000 5th 0.795 Reverse 3.466 Transfer gear ratios Low (4WD) 2.268 High 1.409 Last edited by supazuk94; 10-24-2008 at 09:54 PM. |
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07-22-2004, 04:12 PM
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#22 (permalink) |
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Registered User
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Location: PARADISE GUAM, USA 13N/144E
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suzuki rollover info from...rolloverlawyer.com
Suzuki Samurai Rollover History The Suzuki Samurai was first marketed in the U.S. in 1986 and was sold as a four-wheel drive light utility/sport vehicle in either a convertible or a hardtop body style. The Samurai was marketed exclusively in the continental U.S. by Suzuki of America Automotive Corporation and in Hawaii, Puerto Rico, and the U.S. Virgin Island by Suzuki Motor Company, Ltd. The SJ410 was sold by Suzuki Motor Company in its marketing territory from April 1981 to the present as a four-wheel drive in a convertible, hardtop or truck configuration. The LJ80 four wheel drive vehicle was similarly marketed by Suzuki Motor Company, Ltd., from style. Neither the SJ410 nor the LJ80 were equipped with stabilizer bars or roll-bar assemblies. Even twenty years later, Suzuki vehicles appear to be some of the smallest light utility/sport vehicles ever marketed in the U.S. The LJ80 and SJ410 are more closely related to each other than to the Samurai. Although neither SJ410 are more closely related to each other than to the Samurai. Although neither SJ410 nor the LJJ80 were originally sold in the continental U.S., it appears that some of the vehicles may be have been brought into the continental U.S. from the islands or Canada. Last edited by supazuk94; 10-24-2008 at 09:55 PM. |
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07-22-2004, 04:13 PM
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#23 (permalink) |
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Registered User
Join Date: Dec 2002
Member # 15343
Location: PARADISE GUAM, USA 13N/144E
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more from rolloverlawyer.com
Suzuki Samurai Rollover Concerns When Suzuki unveiled the Samurai, safety experts were shocked that Suzuki would have introduced a vehicle with the same rollover tendencies as the AMC Jeep CV-5 and CJ-7. American Suzuki Motor Corporation however, defends the attacks, charging that the testing procedures used by Consumer Reports and others were biased and completely inaccurate and in fact called such statements concerning the Samurai's high propensity to rollover as defamatory and Suzuki claimed that the rollover tests used were altered to cause the Samurai to rollover. Consumer Reports responded that there were no alterations in the test, as it is the same test as used to test Samurai's competitors. Suzuki Samurai Rollover Propensity - Recall Proposed The Samurai was marketed and sold as a vehicle not for off road use, but instead for highway use. In fact the advertisement on the car buying public was showed the Samurai as a great vehicle for highway trips and commuting to work. The problem however was the vehicle has a high center of gravity and unstable driving characteristics making it not fit or suitable for day to day commuting. The high ground clearance, short wheelbase, narrow track and stiff suspension makes the Samurai somewhat tricky to handle and can behave abnormally in normal accident avoidance maneuvers. Soon after the first Samurai's started to rollover and cause injuries and deaths, consumer groups demanded the recall of the Suzuki Samurai. The recall debate started after the vehicle was given the "not acceptable" ruling by Consumer Reports. A recall unfortunately can not make and fix the problem is inherent in its design, "The only way to fix it is to make the vehicle longer, wider and heavier." The Center for Auto Safety petitioned the National Highway Traffic Safety Administration (NHTSA) to recall the Suzuki Samurai because of safety problems. However, NHTSA on September 1, 1988, denied the request by the Center for Auto Safety to recall the Suzuki Samurai. The Agency agreed to establish a rollover standard for cars and light trucks. Suzuki's continued to sell and market the 1989 model year, with sales as low as 2,000 per month compared to 10,000-12,000 per month a year earlier. Last edited by supazuk94; 10-24-2008 at 09:55 PM. |
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07-22-2004, 04:13 PM
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#24 (permalink) |
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Registered User
Join Date: Dec 2002
Member # 15343
Location: PARADISE GUAM, USA 13N/144E
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Suzuki Samurai - Office of Defects Investigations
In August 1988, the Office of Defects Investigation with the National Highway Traffic Safety Administration (NHTSA) reported a review-of the 113 report Suzuki vehicle rollovers indicated the following: 1) All fatal first event Samurai rollovers involved ejection 2) The average time to failure/time of ownership was less than 8 months, ranging from 2 to 15 months 3) The driver was cited by police in approximately 50 percent of police reported rollovers 4) Alcohol was involved in 50 percent of rollovers described in police reports 5) Where the age of the driver was known, 73 percent of the reported drivers were 25 years old or younger, The oldest driver involved in a single vehicle rollover was 43 years old 6) Limited visibility due to darkness occurred in at least 58 percent of the rollovers 7) There is no seasonal influence (winter, spring, summer, or fall) 8) The average reported travel speed was 37 mph, ranging from 10 to 65 mph. 9) The average reported mileage was 13,090 miles, ranging from 1,618 to 34,000 miles 10) Female drivers accounted for 44 percent of the reported rollovers 11) Weekend rollovers accounted for 44 percent of the reports 12) California accounted for more than twice the number of rollovers as any other state (20 percent versus Florida's 9 percent) 13) A wet or icy roadway or excessively windy road conditions occurred in approximately 29 percent of the rollover It was also determined that when a rollover occurred, the rollover was reportedly preceded by: 1. Loss of control (i.e., spun) - 25 percent 2. Left roadway, straight road - 18 percent 3. Left roadway, cornering/turning - 20 percent 4. Obstacle avoidance maneuver - 15 percent 5. Ramped (struck obstacle) - 8 percent
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DIRT, MUD, ROCKS WHATEVER!!!! |
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07-22-2004, 04:14 PM
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#25 (permalink) |
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Registered User
Join Date: Dec 2002
Member # 15343
Location: PARADISE GUAM, USA 13N/144E
Posts: 2,616
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Suzuki Sidekick & Geo Tracker Roll In
Due to declining sales and threats of continued litigation, Suzuki in 1989 phased out the Samurai and introduced in 1989, the Suzuki Sidekick. Though the Samurai and Sidekick look very similar the Sidekick is 4 inches wider and 200 lbs. heavier than the Samurai is. Built in the new joint Suzuki/GM CAMI factory in Canada, they were briefly powered by the Samurai's 1.3-liter engine, but were soon equipped with a stroked version of that engine, displacing 1590cc and producing 80 horsepower with 8 valves and throttle body fuel injection. The Sidekick's "Identical Twin" the Geo Tracker was sold and marketed through General Motor's dealers in the U.S. The problem with rollover propensity though was not resolved, as the Sidekick and the Geo Tracker, still are tall, lightweight narrow utility vehicles that due to this combination will not escape rollover accidents, but is a vast improvement to the more unstable Suzuki Samurai. Also sold as the Suzuki Escudo in Asia, the Suzuki Vitara in Europe and Australia, the Suzuki Sidekick, Chevrolet, Geo, and GM Tracker in North America, and the Asuna Sunrunner in the South Pacific and Canada, the new Suzuki proved to be another very popular vehicle. A little larger than the Samurai, it made use of independent front suspension, coil-sprung rear suspension, an available automatic transmission, and a much nicer interior. In 1991, Suzuki introduced the long-wheelbase, 5-door hardtop version of the Sidekick, expanding the model lineup into even more upscale territory. In 1995 Suzuki introducted for the decidedly more upscale and the sporty Sidekick Sport. Available in the U.S. with an 1.8-liter, 120 horsepower DOHC inline-4 engine with wide 16-inch wheels. But Europe, Asia, and Australia were given an even better version, dubbed the Vitara LWB V6. Its 2.0-liter 24-valve 4-cam V-6 was Suzuki's largest and most powerful engine yet, producing a smooth 134 hp and a broad torque curve. In 1998 Suzuki unveiled convertible and hardtop Vitara and Chevrolet Tracker, and the Grand Vitara. Suzuki Sidekick & Geo Tracker Rollover Accidents & Roof Crush Injuries As more and more young and unsuspecting drivers get behind the wheel of Geo Trackers and Sidekicks, the more rollover accidents with devastating injuries from ejections and roof crush or roof pillar collapse will occur. The higher rollover propensity of these SUVs is the simple fact that they have a high center of gravity. This is directly based on it's short wheel base and track width. When you put 4 people in a Sidekick or Geo Tracker, the the maximum load capacity of these SUVs are pushed to the limit. When this happens the center of gravity is raised, as is the chances of a rollover of the Sidekick or Tracker. When a rollover occurs, the roof often will collapse or crush into the occupant zone causing serious head and spinal cord injuies. Last edited by supazuk94; 10-24-2008 at 10:03 PM. |
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