Category: Suzuki Tech

      Bolt the extension case back into place and don’t forget the reverse shift rim bolt that we pointed out earlier. Then we concentrate on the shift tower. The shifter locating bolt is a commonly replaced item, as it is very prone to wear. There are two different sizes based on the model […]

  Teflon tape should be a staple in a toolbox. Seal the threads well and install the fitting in the new tapped location. This seal isn’t for air, the system never pressurizes the axle housing. This is more to keep all the lubricant in the housing if you get a little radical on the trails.  […]

       The o-rings are the most critical part of the air seal. When installed, they create an air chamber that ‘floats’ on the bearing journal. The air comes in through the seal housing and is plumbed through the journal wall into the interior of the carrier. Give the o-rings a good coating of oil […]

       Next we go to the front of the transmission and remove the clutch release bearing. Now you can see the 8 bolts that hold the input shaft bearing retainer in place. You will also note that even when the bolts have been removed, it is very difficult to remove the retainer. There […]

       Your rebuild kit should include all of the main bearings as well as the needle bearings, so remember to swap in the new components as you go. As you (carefully) pull the main shaft assembly apart, you will notice three (3) ball bearings in the mix. Don’t lose these. Also, don’t try […]

    ARB Track/Kick Rear Air Locker Project Sidewinder/ARB part 2 with Bill Johnston As Track/Kick owners have noticed, the number of aftermarket traction aids available for the larger rear third member is rising. With the growing number of hybrid rear axles available for the Samurai, this makes the Sammy owners ears perk up as […]

      The factory service manual says to press out the countershaft using a hydraulic press. I accomplished the same thing using a brass drift and a small sledge hammer. Do not use the hammer by itself, you WILL damage the countershaft and you run the risk of cracking the case if you miss… You […]

           Back at the lower case, you can easily remove the reverse gear shaft and idler gear. Set it aside. Next we turn our attention to the countershaft. Using a bearing puller, remove the countershaft rear bearing. This is the first of three bearings you will replace on the countershaft. Being […]