ronin Posted June 25, 2017 Report Share Posted June 25, 2017 Sammy guys have been swapping the Tracker stuff out of the aluminum housing into the Samurai housing as the tracker front will crack under hard use . Google it to see what you will need to do it . Link to comment Share on other sites More sharing options...
SQRLPWR Posted June 25, 2017 Author Report Share Posted June 25, 2017 I don't run it hard....but, the PO had the aluminum housing in when I got it, and it stood up to some I did the swap into a Sami steel housing last year when I replaced the pinion bearing. If anything, I'd like to have a skid for it maybe. Link to comment Share on other sites More sharing options...
SQRLPWR Posted June 26, 2017 Author Report Share Posted June 26, 2017 replaced a bad rear driveshaft ujoint since my diff is still on the workbench lol Link to comment Share on other sites More sharing options...
sar4x4 Posted June 26, 2017 Report Share Posted June 26, 2017 Lots of maintenance! Thumbs up! Link to comment Share on other sites More sharing options...
SQRLPWR Posted June 26, 2017 Author Report Share Posted June 26, 2017 Soon I'll have all new tcase mounts too Thing is super loud with the tcase bolted directly to the frame Link to comment Share on other sites More sharing options...
sar4x4 Posted June 26, 2017 Report Share Posted June 26, 2017 Oh oh! Bolting directly to the frame would eventually result in something breaking! If the engine is on rubber, and the tcase bolted direct, you will break a Transmission or Transfer Case I'll bet! Engines rotate when torque applied. In the extreme case, watch a semi-trailer take off from a dead stop. I'm ordering new Tcase mounts for the Scout. They are rotten rubber! Link to comment Share on other sites More sharing options...
SQRLPWR Posted June 26, 2017 Author Report Share Posted June 26, 2017 you're right. one of the tcase mounts has a hairline crack in it....gonna weld a washer to it when the time comes Link to comment Share on other sites More sharing options...
Lil'monster Posted June 26, 2017 Report Share Posted June 26, 2017 Divorced case shouldnt affect engine or trannie but still should have rubber to absorbe shock load Link to comment Share on other sites More sharing options...
SQRLPWR Posted June 26, 2017 Author Report Share Posted June 26, 2017 ah, yes, but, the stub shaft from the trans doesnt have a slip yoke, so there'll be some transfer of movement, no ? Link to comment Share on other sites More sharing options...
sar4x4 Posted June 26, 2017 Report Share Posted June 26, 2017 24 minutes ago, Lil'monster said: Divorced case shouldnt affect engine or trannie but still should have rubber to absorbe shock load Ooops! I don't know my Samis! lol I learn something new everyday but at this point I also forget something........... No net gain, lol. Link to comment Share on other sites More sharing options...
SQRLPWR Posted June 27, 2017 Author Report Share Posted June 27, 2017 Front end rebuild parts came in ! Link to comment Share on other sites More sharing options...
SQRLPWR Posted July 2, 2017 Author Report Share Posted July 2, 2017 Happy Canada Day! Started to button up the 3rd on Friday - torqued down the cap bolts, and boom....threaded a bolt in the aluminum housing. I was using the service manual torque specs, so it should have been fine. I recall when I removed the bolt initially, it had that stripped feel to it...oh well. So, the carrier and pinion all got swapped into the Sami steel housing after all LOL Installed it all back into the axle housing, RTV and all, and was cleaning up the bench, and the cross pin cap was staring me in the face, so it all came out again in order to install that. It's back in now. Just a few little things left needed to finish, but having a daily driver is making me lazy LOL Link to comment Share on other sites More sharing options...
SQRLPWR Posted July 3, 2017 Author Report Share Posted July 3, 2017 3rd is in now for the final time. I also took the opportunity to install 3 new Maruti Gypsy (Indian Suzuki SJ410 LWB) transfer case mounts to replace the hockey pucks. Test drive is good so far, and it's much much quieter with no warped ring gear and proper transfer case mounts :-) Link to comment Share on other sites More sharing options...
sar4x4 Posted July 3, 2017 Report Share Posted July 3, 2017 Bolts for the pinion / driveshaft flange? Was the pinion side previously threaded? I know nothing about Zuks.... is the spacer factory? Link to comment Share on other sites More sharing options...
SQRLPWR Posted July 3, 2017 Author Report Share Posted July 3, 2017 Threaded bolt was a cap bolt Link to comment Share on other sites More sharing options...
SQRLPWR Posted July 6, 2017 Author Report Share Posted July 6, 2017 Replaced one of the new rear axle wheel seals as it was leaking. I don't know if I damaged the last one when i installed it, but the seal edge had a thin strip coming off it. Thankfully I did the brake backing plate mod last time, so it was all done in half an hour. Let's see how long the new one lasts Link to comment Share on other sites More sharing options...
ronin Posted July 7, 2017 Report Share Posted July 7, 2017 On 2017-07-02 at 9:29 PM, jay said: 3rd is in now for the final time. I also took the opportunity to install 3 new Maruti Gypsy (Indian Suzuki SJ410 LWB) transfer case mounts to replace the hockey pucks. Test drive is good so far, and it's much much quieter with no warped ring gear and proper transfer case mounts :-) any stamp collectors here ? Link to comment Share on other sites More sharing options...
SQRLPWR Posted July 7, 2017 Author Report Share Posted July 7, 2017 pretty much worthless stamps LOL Link to comment Share on other sites More sharing options...
sar4x4 Posted July 7, 2017 Report Share Posted July 7, 2017 Turn them into decals? Lol Link to comment Share on other sites More sharing options...
SQRLPWR Posted July 8, 2017 Author Report Share Posted July 8, 2017 Found a pile of metal paste on the tcase drain, and it seems to be screeming/whining louder on the highway, so pulled it last night. I have 4x tcases, 3x Sami and 1x unknown/1982 case. Gonna swap one in later. Link to comment Share on other sites More sharing options...
sar4x4 Posted July 8, 2017 Report Share Posted July 8, 2017 Uh oh, tick tock! Link to comment Share on other sites More sharing options...
SQRLPWR Posted July 8, 2017 Author Report Share Posted July 8, 2017 Yup. 1am last night I was working on it lol. It's not a huge task to put another tcase back in, assuming number 3 is good. Ive been chasing this whining, and this is tcase number 2 that does it. Apparently the countershaft bearings are known to go and I need this kit http://suzuki.roadlessgear.com/transfer-case-counter-shaft-kit Right now I'm not sure which to install..... 1x early type 1 Sami tcase with the brake 1x '82 sj410 tcase with no 4x4 switch, but with 12% gear reduction (pictured) .... decisions decisions lol Link to comment Share on other sites More sharing options...
sar4x4 Posted July 8, 2017 Report Share Posted July 8, 2017 I start at the Sub tomorrow. I'm assuming it just needs fluid top ups, minor body work, and an inspection. Hope I'm not wrong! Link to comment Share on other sites More sharing options...
SQRLPWR Posted July 8, 2017 Author Report Share Posted July 8, 2017 Fingers crossed! Link to comment Share on other sites More sharing options...
SQRLPWR Posted July 9, 2017 Author Report Share Posted July 9, 2017 Things didn't go to plan with the '82 tcase as one of the selector shafts is jammed solid. So I've moved onto the tcase that was in it originally, with the ebrake on the rear output. All flanges are the smaller type, so im switching spares around lol Link to comment Share on other sites More sharing options...
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