Suzuki Samurai Transmission Rebuild

I'm not sure how long these Samurai transmission last, but mine has at least 135k on it and it's time for a rebuild. Lots of info in the video and resources below if you're looking for parts or information on the rebuild!
LROR Rebuild Guide: blog.lowrangeo...
Rebuild Kit: www.lowrangeof...
DOM Tubing: www.ruffstuffs...
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@fortuneoffroad

[@Z-Bart]

No more growl, no leaks? Job well done.

[@FortuneOffRoad]

Thanks dude! No oil in it yet, but I hope it doesn't leak. My old one was leaking out the rear seal. The intermediate shaft fits snug so we should be in business! 🤙🏻

[@ajfisher2136]

Thanks for doing these videos! They’re great and super helpful.

[@FortuneOffRoad]

My pleasure

[@kellyanderson7115]

I rebuilt mine 20+ years ago, still dry as a bone on the outside and works great. I just refilled it with RedLine MT90, I can't remember what gear oil I put in it after the rebuild. RedLine is highly regarded in the BMW community and I have it in my 330xi, so I figure it should be great in the Sammi trans. RedLine MT90 has a "synthetic" smell that I equate to top of the line. I remember way back when I was a kid and I smelled the Mobil 1 that my dad was using, it had the same smell. Now Mobil 1 doesn't have that smell since they have changed to a cheaper to manufacture formula.

[@FortuneOffRoad]

Next time I swap transmissions I'll have to check that out! Thanks for the info. Always looking for quality fluids to prolong life and increase performance.

[@phuabnomhawjyaj8608]

I use to have same issued when I first started with my Samurai project. Use the Suzuki Sidekick 2wd transmission instead if you upgrade to 1.6L, bigger is always stronger transmission. I did all of that before I swap to the 4wd transmission. The Samurai transmission just too small and the bearing always goes out within 4-5 year if you do more trails run. I don’t recommend 1.3L engine and the Samurai transmission if you’re doing more upgrade for the Samurai. Thanks Kyle!

[@cjjenson8212]

I have no idea why I watched this... Maybe nostalgia 🙄. My sammi is now an EV and I don't have a trans, but it was fun to relive 20 yrs ago 😁.

[@FortuneOffRoad]

EV sounds awesome though

[@cesarsolis1488]

Great job

[@rogeroday9408]

A carpenter hammer? All I can ask is why? I make a plywood top with shaft sized holes in it and wood screw it to the bench. That way you can stand the shaft on end during re-Assy. Just my observations.

[@FortuneOffRoad]

I was using a rebuild guide and these were the tools they used. It seemed to work well. The transmission works well! For the most part...

[@lee85gavaz]

Great job 👏 where the hell do you put the oil on this thing?

[@FortuneOffRoad]

Thanks! There's a plug in the side

[@rolanddisco1257]

Great video! I only took off the back-housing of the gearbox to replace the 5th gear spring. All went fine, but after torqing down the coverbolts, the gearbox turns difficult (before it turns as it should). I think the bearings might not seat correctly in the back-housing? Do they have to get seated after some driving or should everything turn nicely directly after assembly? Any comment or suggestion would be great.

[@FortuneOffRoad]

Everything should work before putting it back in. These transmissions seem to be resilient. You can try running it lightly and just disassemble if its no good. I would ask the Samurai group on Facebook for more info. They are really knowledgeable. 🤙🏻

[@rolanddisco1257]

Found the root cause today. The reverse idle gear has a shim with a kind of keying. The key was not aligned correctly. It caused the gear to get jammed by the shim. All good now gearbox turns freely now 🙂

[@jackpronier8428]

How vital is having a press. I don’t have access to but am looking to change my t case gearing. I have heard this is impossible due to the brains workout a press but I have also heard you can still do it

[@FortuneOffRoad]

If you don't have a press, you can use big hammers for a lot things, but forcing things in that way can damage parts. Pressing them in slowly cab help prevent that. Plus. I use mine for bending steel too. You can find these used on marketplace and craigslist also! 🤙🏻

[@mikezanassi207]

Now why take the shift rails out? Ive seen people do it both ways taking them apart and not removing them. Just curious if theres a benefit to it...

[@FortuneOffRoad]

Just to clean them up and sand them down. This was a junkyard transmission. Filthy!

[@vwbeetlefuelgaugesystem]

Nice video... What did you find that caused the noise... I did not see the little ball bearings for the detent locks..hhahaaaa.

[@FortuneOffRoad]

The grinding noise was from a completely shot bearing on the main shaft of the transmission. Now that it's rebuilt I can hear the problems I have in other places! 😁

[@user-pd1hx4jk6g]

you didnt really show/explain how to take out the clutch release shaft out

[@FortuneOffRoad]

There is a really good guide in the description 👍🏻

[@richardsingh6014]

Ever replaced the extension case bushing? It's been said that a worn bushing causes vibration and leaks..

[@FortuneOffRoad]

I don't know that part off the top of my head, but I changed out pretty much every part I could in a rebuild kit. 🤙🏻

[@richardsingh6014]

@@FortuneOffRoad it's a bushing located behind the rear output seal. It's mentioned in the lowrangeoffraod rebuild manual. But hey if it's working..

[@paulkoh2643]

mine is a 1000cc engine with shorter body gearbox, anyone can advise where can i get my gearbox kit , and which sidekick version is mine belongs to ! :((

[@FortuneOffRoad]

Look around on Suzuki Samurai Owners 2.0 on Facebook groups or Low Range Off Road to see what options they have. 🤙🏻

[@murphymmc]

Nice work, though calling a Samurai a truck is like calling a lizard an alligator.

[@FortuneOffRoad]

It's a bad habit! Rock alligator! 🐊

[@scobbybizkid]

How many working hours did this take you

[@FortuneOffRoad]

Probably about 8. I was doing a little bit after work during the week

[@scobbybizkid]

Did you ever do a transfer case break down / service / rebuild that you can share ?

[@SamuraiLWB]

Where do I put the oil?🙈

[@FortuneOffRoad]

There is either a 15/16" hex head on the side or a 3/8" square for a socket. 🤙🏻

[@austinwise9987]

What trans fluid do you run

[@FortuneOffRoad]

Inuse the STP 80/90 gear oil, you?

[@austinwise9987]

@@FortuneOffRoad I use the redline mt-90. The stp 80/90, at least the only ones I can find around here are gl-5. The samurai calls for a gl-4 API rated gear oil for the trans because it has brass synchros and the gl-5 stuff will eat them up overtime. I called stp and pennzoil and asked if there gl-5 was “yellow metal safe” and they both said no so I play it safe and use a gl-4. It’s super hard to find gl-4 oils anymore as there isn’t many vehicles that require it. So I play it safe and don’t use the GL-4 stuff

[@jimbot168]

You might get a kick out of some videos I took of a bud of mine's Sammy trip on the Rubicon Trail, calif. In these videos he was running 4.16's tcase, rear locker 91 1.3 FI... Pretty harsh attacks on the BIG rocks. We did 2 trips, then he did 6.1's... Way more comfy. He passed away last year. Reddog1 on the Z forums. kzbin.infovideos

[@FortuneOffRoad]

Sounds like some cool stuff. I'll check it out! Thanks

[@klumsytone]

So you rebuilt the Samurai’s transmission before the Suburban? Bring the back the Suburban.