Transfer Case Assembly Video

Chris Geiger

Chris Geiger

Well-known member
I have started putting together a set of video instructions for the Samurai tcase. So far I just have the video done and don't have any audio. Here is the current work...

http://www.trail-gear.com/videos/samurai-tcase.wmv


To finish the audio part I need a Samurai service manual to properly identify the parts. Does anyone have a link to a pdf of the factory service manual for the case that I could use?
 
Nice Video

      Another great product of a Great Company I have one of your gear sets and I love them.


                              Thanks Fox
 
great job, don't think i would like the audio, this is so much better than the paper photos printed off the computer
 
The scanned manuals from Zukboys are exactly what you want.

http://www.suzukiinfo.com/

Either of these two from the previous link are the best:

1987 Samurai Factory Service Manual: Suzuki's Factory Service Manual. This is one of the best versions of the best reference book. Adobe PDF format contained within a ZIP file, 1 part, fully searchable and linked, no encryption. 350.1MB

http://www.suzukiinfo.com/sierra/zukboysfsm.zip


1986-1988 Samurai Factory Service Manual: Suzuki's Factory Service Manual. This is another great version of the best Suzuki references available. Adobe PDF format contained within a ZIP file, 1 part, fully searchable and linked, no encryption. 254.3MB

http://www.suzukiinfo.com/sierra/1986-1988samuraifsm.zip
 
I'll be posting the finished version (with audio) on YouTube when it is done. I'll be posting it under Trail-Gear along with the other videos I put there.

The version posted here is much cleaner. Youtube videos have a lot of static on them.

We will also be including a full tv size version on DVD with the gear sets! Just drop the cd into your dvd player and watch it.
 
excellent video  just what i need as in a couple of weeks i will be doing my xfer case with a rebuild and 6.5-1 gears from trail gear    thanks very much keep em coming
 
Great vid. I have to add that I think the most important part was left out which is in the disassembly, when the gears are pulled off. If the small needle bearings in the double geared shaft are messed up. You are going to be looking for another case or another shaft. This was a great vid though. Thanks for taking the time to show how simple these are to work on
Brian
 
Nice video. I would also like to show how to dissasemble it and the tools needed.

One thing you didn't address is the side play in the gears. I saw no shims being used or how you checked it. If you are reassembling with all the same parts then it may not be an issue. I had shims that were trashed though. Tom at Spidertrax suggested to me to dry fit the case with no gasket or shims and measure the gap between case halves, subtract the thickness of the gasket and there is your shim thickness.

Another thing, you don't want to ever hit a bearing on the race that has no resistance on it like you did on the F. output shaft bearing. There is little resistance on that bearing as I remember but it is still good practice. You don't want to burnish the bearings or races.  I prefer presses to put bearings on.  A seal installation tool is nice as well.

Other than that, Thanks for the vid.
 
sweet vid. i thought i was going to need it when i was going to get the 6.5 gear set but lucked up big time and found a complete t case with calmini 6.5 gears for $550!
 

https://www.helpavetshine.us/help-a-vet-shine
Back
Top Bottom