Suzuki Samurai Transmission Rebuild

How to rebuild a Suzuki Samurai Transmission, tear down and rebuild with new bearing, seals and Synchros. All parts wer bought from www.Roadlessgear.com
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/ fabbinadventures
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Check out my latest video: "Hybrid Diff Part 3: Trussing and Armor"
• Suzuki Samurai Hybrid ...
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[@fastback777ray]

Thanks ...i was looking for this kind of a transmission rebuild. Keep posting & stay safe

[@FabbinAdventures]

Lots of content coming, Thanks for watching Fabbin Adventures!

[@19frito]

Awesome video thanks for taking ur time n doing it right

[@FabbinAdventures]

You bet man, i like to help when i can! Thanks for watching Fabbin Adventures!

[@TheAlaskaCajun]

well I guess I'll be doing this on the Sammy I bought yesterday.... thanks for the video, it looks pretty straight forward.

[@FabbinAdventures]

Yeah, it really is pretty easy to do, just keep every thing in order and watch for them little steel balls. Thanks for your comment!

[@mechanicaldudeag]

Thanks for this vid bro. Just Rebuilt my Tracker 5 speed and it was a great help

[@FabbinAdventures]

Awesome, glad to be able to help!

[@20tea]

Thank you so much for going through this! I have a rebuild kit and plan on doing this as well. Got 2 transmissions to reduce down time. Love how small and manageable these transmissions are too. A press and a 3 arm puller does wonders with this too. T case rebuilding is super easy as well. I've rebuilt 10 or so from friends and acquaintances. I know my samurai inside and out the past 20 years. Very few thing left untouched and updated.

[@FabbinAdventures]

No problem man! I love how easy things are to work on also! I am building a 1972 FJ40 and while its simple, the parts are big and heavy! Thanks for watching!

[@juanbeltran3634]

Nice video man need to get my done to!

[@FabbinAdventures]

Thanks man, hope it helps you, it made a big difference to mine! Thanks for watching!

[@genemullins]

Thanks for this channel...watch it often. My 87 JX was making the same noises with clutch in and out changing/reducing the noise. My 5th gear was always extra noisy too. not sure why. Now I'm brave enough to try the rebuild. Manuel Mullins

[@FabbinAdventures]

Thanks for watching and commenting! Im glad i can inspire people to work on their own rigs!

[@keyworksales6241]

Hey man thanks to you I pulled my transmission out myself and I'm rebuilding it now. I've rebuilt engines before but nothing this extreme. It ain't bad I think my locator bolt is broken and the shifter sheet grenaded itself, but other than that it's all good. You inspired me and its going well 👍

[@FabbinAdventures]

Awesome! If you have rebuilt motors you can rebuild these little transmissions, good to hear you are getting some value from my videos!

[@4LO_Jeep_Bro]

I had the same sound. I swapped the pilot and thowout bearings but it remained. Rebuild did the trick.

[@FabbinAdventures]

Glad it worked out for you, its actually pretty simple to rebuild the transmission! Thanks for watching Fabbin Adventures!

[@renebarraza1585]

awesome thanks.

[@FabbinAdventures]

No problem, hope it helped! Thanks for watching, subscribe and share if you haven't already!

[@meduse1111]

very good vide thanks

[@FabbinAdventures]

Your welcome, thanks!

[@brauliocastro9070]

VERY GOOD

[@FabbinAdventures]

Thanks!

[@brockukg]

hey from the UK, in the beginning stages off my 16v swap on my 92 Samurai called Suki! got a whine coming from the gearbox when in 5th so this will be super helpful for when i pull the transmission out. loving the content :)

[@FabbinAdventures]

Glad you are enjoying the channel and that it helps you out. Your gonna love that quiet transmission, i sure do! Thanks for watching!

[@t.j.goldwater7139]

Hey! How did it go? Did you get rid of the fifth gear whine?

[@FabbinAdventures]

Oh yeah, noises are gone, shifts like brand new! Thanks for watching and commenting!

[@t.j.goldwater7139]

@@FabbinAdventures ​ Great you’ve managed ! But I was curious about how it went with @borckukg. Seems like he had the same sound/state of gearbox as my newly acquired sj413. If it’s still a bearing problem with 5th gear whine. But thanks for snappy reply, you’re really on it! 😁💪

[@FabbinAdventures]

I try..lol

[@JAAZven]

Nice job..!

[@FabbinAdventures]

Thanks man, shake down run yesterday went awesome! So quiet now!

[@JAAZven]

@@FabbinAdventures when are you going to install the blocker ..?

[@FabbinAdventures]

Gonna be a few weeks yet, im waiting on parts for the diff build.

[@JasperMaakt]

Mine starts to make that noise too. Not so much yet though… but I especially hear noises when I let go of the gas in third and the car slows itself down on the engine… and transmission… I think it’s the same totally shot baring you replaced at the front… guess I have to take it out within a few months. Thanks for this vid. Make me more confident to try it

[@FabbinAdventures]

Yep sounds like you have a trans rebuild in your future. It is a pretty easy job, take video as you go or pictures, use the wire technique to keep things in order and you'll be fine! Im glad my videos help, thanks for watching and commenting!

[@daneast]

I didn't have any issues using just a gear puller and tapping bearings off and on as needed. A press really isn't needed. I only had one single bearing that was tougher to break loose than the others, but it really isn't hard to apply the impact to just it and the shaft. Some were so easy to remove I just held the gear puller with my hand and tapped the shaft with a dead blow hammer and it moved nicely each impact. One note is that the gear hubs / sleeves can come apart, and there are few spring rings and parts that need to be put together correctly. Also those springs can come out of position without it being obvious, so those really need to be inspected and snapped into place if they got moved around during disassembly.

[@FabbinAdventures]

Definitely, i use a press for many other things so i used it here, not needed if i remember right, been a while since i rebuilt the tranny.

[@Tunzbig]

Nice work.bud :)

[@FabbinAdventures]

Thanks man, its actually pretty simple

[@Tunzbig]

@@FabbinAdventures stay strong king

[@FabbinAdventures]

We are trying!

[@alexisp.9387]

great job congratulations, you can leave a link where to buy the complete transmission overhaul kit. I can also ask you who is the band you have as a musical base initially in the video, thanks.

[@EivinSukoi]

Good job mister , hopefully when we go back to work Iam gonna be able to scrape some money for my projects , right now we are in " Survival mode , like naked and afraid " sort of situation . This Covid-19 is causing so much struggle for the working community . Anyway , keep up the good work , but. Still think that installing a power steering is for women . By the way my " Prius" steering pump came a week ago . Greetings from Taxachusetts .

[@EivinSukoi]

Hey quick question , do you use acetone when you remove your nail polish , or you use your best friend nail polish remover from " Costco"?.

[@reiestrada9167]

like a master, WAYY helpful content, congratulations Mr. Rob, great great job, that's what im gonna do, i got this issues on 5th gear, it just doesnt get in, and pretty close lever position to 3th gear, should i got dissamble entire unit?

[@FabbinAdventures]

Thats hard to say, but probably. My transmission was easy to shift, but it sure made some aweful noises. Been quiet ever since i rebuilt it and shifts like new!

[@richracing7420]

Excellent. Nice to take a look. Got a nasty whine in 5th gear. Got some work to do

[@FabbinAdventures]

Its actually pretty easy to rebuild! Thanks for watching Fabbing Adventures!

[@richracing7420]

@@FabbinAdventures My issue is determining the difference between the samurai and the jimny transmission on my imported one I'm thinking of buying a samurai rebuild kit and going for it, as most likely its the bearings causing the whine in the transmission.

[@FabbinAdventures]

Well if you have the time you could pull it apart, find the bearings giving you trouble and just locate and order the specific bearings, and install them. Does it make the whine in all gears or just one or 2?

[@richracing7420]

@@FabbinAdventures1rst and 2nd good. 3rd it lightly crunches in. 4th is good and then 5th it whines (loudly). Was told it's possibly the transfer case also.

[@keyworksales6241]

@@richracing7420 did you figure it out?

[@yadinganon5037]

Can you write a long term review on the rebuild?

[@giusepearturo]

thanks man, the link to the bearings and syncros woub be nice

[@FabbinAdventures]

Will do later today, headed out on the jet boat right now

[@gerardosalas3930]

Great vid. Mine is leaking and I think it is the bearing. Would love to fix it myself but I have never removed a gear box and I am afraid to screw up.

[@FabbinAdventures]

Where is it leaking from, if its a rear slip yoke seal, its easy, pull the old and replace with new. If its a front seal or anything else the transmission will have to come out. Thanks for watching Fabbin Adventures!

[@gerardosalas3930]

@@FabbinAdventures Hi man, thanks for answering. Actually both ends are leaking. The rear is leaking and noticed the front too, around the oil pan. Greetings from Costa Rica.

[@FabbinAdventures]

They are simple seals to change but the front requires removing the transmission. If you do that you may as well check the bearings inside and replace if any have play. Maybe even replace the clutch if your not sure how many miles or kilometers are on it. Thanks for watching Fabbin Adventures

[@jaymurray5790]

hi i would subscribe watch and listen to your post but with the way my hearing is i cant separate you from the background music. keep moving forward.

[@FabbinAdventures]

Watch my newer videos, the old stuff sucks, had lots of trouble with the audio back then. Thanks for trying to watch.

[@connorables6531]

very helpful video, I'm in the process of rebuilding my trans on my 87 samurai. but im having issues finding a new 5th and reverse gear and synchro hub.due to previous owner shifting it from fith to revers wile going down the road. is there any website out there that might sell what im looking for?

[@FabbinAdventures]

Oooo, thats a tough one man, ive never seen new gears, im thinkin your gonna need to find a used one and rebuild it. Thanks for watching fabbin adventures!

[@user-yu7ye8bm9y]

inside is very similar to JA11,JA22 trans.

[@jamesdahmer5027]

hey buddy interesting question - I've put a 2wd sidekick transmission into my samurai (for an ALH TDI swap) and I had the original samurai driveshaft adjusted... I've replaced the rear seal as it was definitely do... and I can't seem to get the transmission/driveshaft to seal! I'm told the yoke of the driveshaft out of a 2wd suzuki is specifically larger (1 7/16") than the stock samurai of 1 1/4". My seal however is the correct size for the transmission and the yoke, but I still have leaks. I'm told it's because of the length of the yoke not mating with a "brass plug" at the tail of the transmission is this so? Thanks!

[@andreamarrucci7488]

Hai dei suggerimenti da dare per staccarla dal motore in modo che non caschi in testa? Il video della rimozione lo hai saltato..grazie,comunque anche io proverò a farlo da solo,ho tre giorni liberi e ci proverò!

[@1995phxBahls]

any info on the output shaft bushing. i have already installed the transmission and after some research found it has to be reamed to size.

[@FabbinAdventures]

Not sure what you are talking about.

[@bryanwoodhead6490]

Is this the same transmission in a 2001 geo tracker 2.0 5speed. I need to replace front input bearing I see its quite easy if you know your way around just want to be sure I'm watching one on right transmission

[@FabbinAdventures]

No its not, but i am told they are pretty similar. Thanks for watching and commenting.

[@austinwise9987]

I have No transmission experience but this seems really easy. To easy….

[@FabbinAdventures]

It is pretty easy, ive only had a few manual transmissions apart before this one. Im sure you can do it!

[@JV-ph7en]

When you said you pressed the bearings back on did you just tap them all on with a deadblow? or did you use a full on press to push them back on?

[@FabbinAdventures]

I used a cheap little 12 ton press. Thanks for your comment!

[@daneast]

How difficult was it to turn the input shaft by hand after torqueing down all the case bolts? When I had it all assembled, but not torqued down, I could easy turn it with my fingers. After torqueing it (19 ftlbs) I have to grip it pretty tight with my hand to rotate the input shaft. I can shift through all the gears, and turn it in every gear, but it's got a lot more resistance once torqued. The case parts went together easily without even having to tap them.

[@FabbinAdventures]

To be honest i dont remember, a buddy of mine suggests tapping the input and output with a dead blow hammer to seat things. I would think the fact that you can still turn by hand its a good thing. The final torqing should get all bearings into "spec" and there should be some resistance as there are a bunch of gears turning in there and the bearings are "set" Sorry i cant help more.

[@ericfgj]

what kind of oil did you use in your transmission I do not know if use GL 4 or GL 5 on it, can you help?

[@FabbinAdventures]

Ooo i cant remember off hand but a quick google search says gl4 is what you want. Thanks for watching and commenting!

[@daneast]

Finally got my 1.6 swapped in along with the transmission rebuild while I had it out. I have a potential issue. First gear is making a whining sound. Does it under power, or if I push clutch and just coast in first gear. It is reminiscent of the whining you get in reverse. Gets higher pitched with speed. I'm afraid I'm going to have to pull the transmission and open it back up. Is this normal with a rebuild and things have to kinda wear in? If I jiggle the shifter (while in first gear) it gets louder in different spots as I move it around.

[@daneast]

I put the collar gear on between 1st and 2nd facing the wrong way. I even double checked this after hearing about this issue, but I incorrectly assumed all three collar gears faced the same direction. Hopefully it's not too hard to drop the transmission. I just installed it already mated to the engine, so now I'll get to experience it the other way.

[@FabbinAdventures]

No, it should be quiet, and the shifter should "click" into gear.

[@edwinmontes6588]

do you know where can a find the transmission kit for Suzuki Maruti 800 ?

[@FabbinAdventures]

No, i have no idea, sorry

[@allengonzalez3253]

How's it going Sir, can you reuse the c clips ?

[@FabbinAdventures]

Yes i think you can reuse the clips as long as your careful not to over stretch them. Thanks for watching and commenting!

[@beekeeper7535]

My 88 Suzuki samurai makes a whining noise in 4th gear mainly when climbing steep hills at 3/4 to full throttle. Really don't hear the noise nearly as much in other gears. I'm pretty sure it's coming from the transmission and not the transfer. Years ago I remember my 1986 Toyota truck used to make a similar noise just not nearly as loud. Trying to figure out what's going on with it. I drive my samurai 42 miles one way to work everyday gotta jump on the interstate for roughly 7 miles the weirdest thing happens people wave at me with their middle finger while blowing the horn I guess there trying to tell me how much they like my samurai. I still run the original 1.3 liter beast under the hood.

[@FabbinAdventures]

Likely a bearing going out in the transmission, though the drive train of these samurais do have a whine to them naturally.

[@CaptainGSR]

My 87 does the same thing. I wish there was a way to replace the input shaft bearing without taking the whole damn thing apart...

[@FabbinAdventures]

Yeah but its a simple job to take apart and rebuild, for peace of mind if nothing else. If that bearing is going out its only a matter of time till she implodes! And if it is getting bad, there could be other things that need attention in there.

[@hebdomatical]

It appears your transmission may have been rebuilt before with the large sealed input shaft bearing. I didn't believe they come that way and the one you replaced it with was open to let the oil in and out. edit: I've now seen two videos with the red sealed input shaft bearing. Totally confused.

[@FabbinAdventures]

I would think you would want oil to be able to get in there, though if you have metal contaminents in the oil it will ruin the bearing, if it ruins that one it will ruin all of them. Thanks for your comment!

[@user-ed8gg7yy8b]

Does the Tracker have the same transmission?

[@FabbinAdventures]

It is different, sorry

[@shanahardy5228]

I have a 1987 Samari that keeps piping out of 5 gear can fix in car

[@FabbinAdventures]

Nope, tranny will have to come out.

[@xXZ31t6esTXx]

Prelup the bearings with what?

[@FabbinAdventures]

I used a lithium grease, but you could just use gear oil, or some type of assembly lube

[@samikhattak2589]

Is it possible Suzuki sumorai 4 speed manual transmission convert to 5 speed ??

[@FabbinAdventures]

I doubt it, never even heard of a 4 speed manual in a samurai.

[@richardsingh6014]

Did you replace the extension case bushing?

[@FabbinAdventures]

Im not sure which bushing your talking about. If its not on the video, i probably didnt do it.

[@richardsingh6014]

@@FabbinAdventures it's the bushing located where the prop shaft yoke slides in right behind the rear output seal.

[@FabbinAdventures]

Nope i didnt even know there was one there and it never came with the rebuild kit. Thanks for watching

[@ARLI919]

İf you decrease music level, it will be very good.

[@FabbinAdventures]

Ill have to check it out but i thought i have volumes pretty equal in my latest videos. Thanks for the comment!

[@harleystewart4344]

You shouldn't have used that grese to lubricate you gears as it will become a sludge in your transmission . The best way to lubricate them for installation is to have a container and fill it with transmission fluid and dip your gears in

[@FabbinAdventures]

I changed it out after my shake down run for clean new synthetic, shoulda mentioned that was the plan, sorry, but good catch! I prefer to grease like that so i dont have a mess on my mating surfaces that i gotta clean or habe a potential leak. Thanks for watching Fabbin Adventures!

[@brandonfrancesconi-tn6gj]

I am currently rebuilding my 88 samurai transmission. I used grease to prevent dry start as well. What is your shake down process? How long after I put the transmission in should I change the fluid to prevent slug buildup from the grease?

[@FabbinAdventures]

I personally dont believe the grease will cause any harm, but if your concerned, you can do an " oil change " after a goon run with it.

[@austinwise9987]

So I just did mine and the input and output shafts turn with the top off the tranny. But once I bolt every thing back up I can’t spin the shaft by hand. Any ideas?

[@FabbinAdventures]

Good question, is it in neutral? Can you turn it at all? Even with a wrench?

[@austinwise9987]

@@FabbinAdventures thank you for the response! But yeah it’s in neutral. I shifted through all the gears and put it back in neutral before I pulled the back housing and top back off this morning. When I took them both off, it spins fine. I’m at a complete loss as to why it’s not spinning once it’s all back together. And I didn’t turn it with a wrench I didn’t want to mess something up by forcing it

[@FabbinAdventures]

I would attempt to turn it with a wrench just dont over do it. You can apply alot more force with just a little push on the wrench. Not reall sure what would bind just by putting the covers on. It may load the bearings once torqued down and make it a little harder to turn.

[@zazazizo6958]

Pajro

[@codyswilley]

First

[@FabbinAdventures]

Damn your quick!

[@codyswilley]

@@FabbinAdventures gotta be quick lol.

[@birimrachacheranmomin3540]

So there's six bearings inside the transmission right?

[@FabbinAdventures]

What ever you see in the video is what its got. Thanks for watching and commenting!

[@birimrachacheranmomin3540]

@@FabbinAdventures how's the transmission after the build ? Does it still have that some sound coming from it?

[@FabbinAdventures]

Nope nice and quiet, nice precise gear selection instead of sloppy too!

[@birimrachacheranmomin3540]

@@FabbinAdventures That great man 👍, I just got mine rebuild today, it still has some noise coming from it but much quieter than before

[@FabbinAdventures]

Good deal, mine was really growling, that bearing didnt have much life left to it!

[@mauriciocastro2347]

Hi, which was the brand that you use for the rebuild kit, so don't buy that ahahaha, just joking. I agree with you should be nice to have all that cage bearings. like the video!

[@FabbinAdventures]

I bought the transmission kit from RoadlessGear.com, all the kits from all the vendors seem the same. The cage bearings should be included! Thanks for watching Fabbin Adventures! Subscribe if you havent already, im putting out videos every friday.

[@mauriciocastro2347]

Thanks!!!!

[@joelgraba1077]

Mine just started wining :( and no its not the throw out

[@FabbinAdventures]

Time for a rebuild i guess, its easy! Thanks for your comment!

[@suzysuzuki8865]

Could I get away with doing this without a press?

[@FabbinAdventures]

You might be able to do it with out a press...maybe. but even a cheap little press would be worth it to invest in. Thanks for watching and commenting!

[@horacerumpole6912]

chi-com bearings-done-fail-out!

[@FabbinAdventures]

Yup they were shot! Thanks for watching!

[@horacerumpole6912]

@@FabbinAdventures Referring to the new ones-

[@6Sprocket]

throw out bearing...

[@FabbinAdventures]

Thanks tips!

[@shtfvan8084]

Question.. how come so many "rebuilt transmissions fail? Seems like so many companies list "rebuilt" transmissions that end up being shit. So are we talking shitty rebuilds, or what? Seems like a new one is the way to go.. no?

[@FabbinAdventures]

Yeah it seems to be an unfortunate fact that rebuilds are never as good as the original equipment. When i take my trucks inbfor work i demand oem parts be used, the aftermarket parts just dont stand up and you end up buying them again. In the case of a samurai transmission, they are not made anymore so you have to rely on rebuild kits and quality work and attention to detail. I would have liked to see all new japanese bearings in this kit, not have some and some bearings marked "made in china", we all know what that will mean down the road.... Thanks for watching and commenting!