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Old 12-29-2009, 01:31 AM   #1 (permalink)
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Default What else should I replace when I have tranny out? 86 Samurai

I ordered parts to rebuild my tranny, transfer case, and clutch. While I have it all apart, is there anything that is not normally part of the rebuild kits that I should also swap out before I put it all back together? I read something about a bushing in the transfer case that can cause a problem. Don't recall exactly what that was now. I guess there is also a pin that can break in the tranny shifter. Don't want to spend much $$$ but don't want to get stranded in the middle of nowhere either due to some relatively inexpensive part going out. Suggestions and links to those parts is appreciated. Thanks!
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Old 12-29-2009, 03:29 AM   #2 (permalink)
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Default tranny parts to replace...

Brass Transmission Shifter sheet $18.95
Brass Transfer case shifter sheet $12.00

ZOR Zuks Off Road

Shifter bolt

Hawk's Strictly Suzuki 888 SAMURAI or your Suzuki dealer. Probably under 20 bucks.

The above can be replaced with transmission/tcase installed. All prices US.

Tell them Ack's FAQ referred you.

Don't forget the pilot bearing! It may or may not be part of the clutch kit so be sure you are getting one.

I hope that this helps!
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Old 12-30-2009, 04:08 PM   #3 (permalink)
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Quote:
Originally Posted by ack View Post
Brass Transmission Shifter sheet $18.95
Brass Transfer case shifter sheet $12.00

ZOR Zuks Off Road

Shifter bolt

Hawk's Strictly Suzuki 888 SAMURAI or your Suzuki dealer. Probably under 20 bucks.

The above can be replaced with transmission/tcase installed. All prices US.

Tell them Ack's FAQ referred you.

Don't forget the pilot bearing! It may or may not be part of the clutch kit so be sure you are getting one.

I hope that this helps!
Ordered both from Zor and the gal there said she wondered how you came up with the name "Ack's FAQ." : )
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Old 12-30-2009, 08:06 PM   #4 (permalink)
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Early Zuks (<88.5?) used an 8mm transmission shifter locator bolt, which is prone to breakage. What's worse, the broken tip can easily fall down into the case where it could do a lot of damage. The bolt is cheap, so replacing it before it breaks might be a good thing. Later transmissions use a modified shift tower, shifter and larger 10mm shifter bolt and so don't break there. HawkSuzukiParts offers a shift pin repair package that upgrades your early parts to the later & stronger configuration. It's worthwhile looking it over, if only to understand what's involved.

Edit: The clutch actuating rod passes through an aluminum plate which kinda acts like a bearing. After a while it can gall and grab the rod, making the clutch operation stiff. It did on my rig. Petroworks makes a brass sleeve to fix this. Visit: "http://www.petroworks.com/pdf/Transmission Case Figure 24.pdf"

Last edited by Merlin93; 01-01-2010 at 10:56 PM.
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