Category: Suzuki Tech

           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 […]

      The needle bearings should slide easily with no obstructions. And don’t forget the circlips as you go. Remember the input shaft we set aside earlier? You will need to replace the bearing on the end of the input shaft. Use a bearing puller for removal and then press the new bearing into […]

          Here we finally close up the case by replacing the input shaft housing.  Finally a new clutch release bearing (aka – the throwout bearing) tops off the input shaft. Remember to replace the pilot bearing in your flywheel also, or you may experience a situation where the vehicle still wants […]

           When you first look at the main shaft, it may appear very daunting. But as long as you have a large workbench where you can lay everything out in order (and you have your Factory Service Manual handy) it’s not really tough. This is actually two shafts. The main shaft […]

      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 remove the ring gear bolts and carefully remove the ring gear, setting it aside.  Now we turn our attention to the ARB Air Locker. You will notice when you press the bearings back on that one of the bearing journals is longer than the other. This is the way they get the air […]

      with Brent May GRIZZLEY FAB TRAC-BAR INSTALL   After experiencing a few slightly tweaked rear springs, and deciding to go with a softer CJ spring set up on my 88.5 Samurai, I decided that a trac-bar would probably be a good addition to my rear suspension. I began by looking at a […]