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Discussion Starter #1
How easy is it to change the transmission "shifter sheet"?

Can anyone post a link to some installation instructions or give me some tips? I haven't been able to find them online.

I received my new transfer case "shifter sheet" yesterday. When I first bought the Zuki, it only took me a day or two to lock up the transfer case. I took the shifter out, repositioned the rods, reinstalled and it's been fine since because we leave it in 4wd-LO .... until my neighbor, convinced that we were in 4wd-HI and not LO, moved the x-case shift lever and locked it up again. So I pulled it apart, repositioned, reinstalled again. There has never been so much as a remnant of the original so I didn't realize at first anything was missing. I'm confident I can have the new "shifter sheet" (what an odd nomenclature) installed in a few minutes.

But the transmission is just as sloppy and the 'sheet' is almost as inexpensive as the one for the xfer case.

Is it as easy to change? Take off the boots, push and twist a lock, pull the shifter out, put a 'sheet' in, put it back together? If it's very complicated, we can live with it as it is but if it's as easy as the xfer case, I'll put a new 'sheet' in.

Phil
 

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yes the transmission sheet is just as easy as the transfer case. but if your tansmission is sloppy there is a bolt in the shifter that might need replaced to. the bolt is easy to get to and cheaper than the t-case sheet.

this web site has the t-case sheet and a kit to fix your transmission

Suzuki transfer axle gear kits

and this web site shows the install for the t-case sheet

RRO Shifter Sheet - Trucks 4x4 @ Off-Road.com

hope this helps
 

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Discussion Starter #3
Thanks hotrodsami.

I was wanting to make sure the fix for the transmission wasn't very involved either. I appreciate the links.

Phil
 

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There are also "25-year" parts for both in brass from Myron at ZuksOffRoad (ZOR).
ZuksOffRoad
The early Zuks had a small 8mm shifter locator bolt, which often breaks (be SURE to remove the broken tip). Later (88.5+) Samurais had a larger 10mm bolt which doesn't break. Hawk sells an upgrade kit, 'cause you have to change out (re-machine) the shifter and shift tower to accept the larger bolt. It's currently on the specials page at HAWK STRICTLY SUZUKI
 

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Discussion Starter #5
Thanks for that info Merlin.

I might have considered the "upgrade" but it's a done deal now. I put the new bolt and sheet in last Friday.

And the bolt tip WAS indeed broken off, and I couldn't retrieve the broken piece. I took off the part the bolt goes into, looked long and hard, but never found the missing chunk.

All I can do at this point is hope it fell to the bottom of the tranny and won't get caught in the gears.

Phil
 

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...And the bolt tip WAS indeed broken off, and I couldn't retrieve the broken piece. I ... looked long and hard, but never found the missing chunk. All I can do at this point is hope it fell to the bottom of the tranny and won't get caught in the gears. Phil
You may be able to fish or flush it out through the drain plug. If it bounces around and gets caught in the gear teeth, you'll have a lot more (expensive) work to do. Some kind of magnetic device attached to the drain plug might hold it until you get it out. Perhaps a rare-earth (neodymium-iron) disk magnet could be epoxied to the drain plug. I see the disks at the swap meet for a buck or two.
 

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Discussion Starter #7
Good idea on the magnet Merlin. I'll start planning on that, first finding a suitable magnet.

Phil
 

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most transmission drain plugs are magnetic from the factory but it's never all that strong a magnet. go a head and pull it out and see if you find it(or can flush it out) but if you don't have any luck get a stronger magnet and try it.

good luck
 
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