Suzuki Samurai Transmission Rebuild

Рет қаралды 57,687

4 жыл бұрын

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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Пікірлер: 143

@20tea 3 жыл бұрын

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 3 жыл бұрын

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!

@keyworksales6241 3 жыл бұрын

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 3 жыл бұрын

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

@mechanicaldudeag Жыл бұрын

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

@FabbinAdventures Жыл бұрын

Awesome, glad to be able to help!

@fastback777ray 4 жыл бұрын

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

@FabbinAdventures 4 жыл бұрын

Lots of content coming, Thanks for watching Fabbin Adventures!

@4LO_Jeep_Bro 4 жыл бұрын

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

@FabbinAdventures 4 жыл бұрын

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

@genemullins 2 жыл бұрын

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 2 жыл бұрын

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

@TheAlaskaCajun 3 жыл бұрын

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

@FabbinAdventures 3 жыл бұрын

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!

@brockukg 3 жыл бұрын

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 3 жыл бұрын

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 Жыл бұрын

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

@FabbinAdventures Жыл бұрын

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

@t.j.goldwater7139 Жыл бұрын

@@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 Жыл бұрын

I try..lol

@19frito 4 жыл бұрын

Awesome video thanks for taking ur time n doing it right

@FabbinAdventures 4 жыл бұрын

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

@alexisp.9387 2 жыл бұрын

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.

@juanbeltran3634 3 жыл бұрын

Nice video man need to get my done to!

@FabbinAdventures 3 жыл бұрын

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

@JasperMaakt 2 жыл бұрын

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 2 жыл бұрын

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!

@reiestrada9167 3 жыл бұрын

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 3 жыл бұрын

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!

@daneast Жыл бұрын

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 Жыл бұрын

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.

@EivinSukoi 4 жыл бұрын

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 4 жыл бұрын

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

@meduse1111 3 жыл бұрын

very good vide thanks

@FabbinAdventures 3 жыл бұрын

Your welcome, thanks!

@renebarraza1585 3 жыл бұрын

awesome thanks.

@FabbinAdventures 3 жыл бұрын

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

@gerardosalas3930 4 жыл бұрын

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 4 жыл бұрын

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 4 жыл бұрын

@@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 4 жыл бұрын

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

@connorables6531 3 жыл бұрын

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 3 жыл бұрын

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!

@yadinganon5037 3 жыл бұрын

Can you write a long term review on the rebuild?

@brauliocastro9070 4 жыл бұрын

VERY GOOD

@FabbinAdventures 4 жыл бұрын

Thanks!

@JAAZven 4 жыл бұрын

Nice job..!

@FabbinAdventures 4 жыл бұрын

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

@JAAZven 4 жыл бұрын

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

@FabbinAdventures 4 жыл бұрын

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

@giusepearturo 4 жыл бұрын

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

@FabbinAdventures 4 жыл бұрын

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

@richracing7420 4 жыл бұрын

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

@FabbinAdventures 4 жыл бұрын

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

@richracing7420 4 жыл бұрын

@@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 4 жыл бұрын

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 4 жыл бұрын

@@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 3 жыл бұрын

@@richracing7420 did you figure it out?

@Tunzbig 2 жыл бұрын

Nice work.bud :)

@FabbinAdventures 2 жыл бұрын

Thanks man, its actually pretty simple

@Tunzbig 2 жыл бұрын

@@FabbinAdventures stay strong king

@FabbinAdventures 2 жыл бұрын

We are trying!

@JV-ph7en 3 жыл бұрын

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 3 жыл бұрын

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

@1995phxBahls 3 жыл бұрын

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 3 жыл бұрын

Not sure what you are talking about.

@daneast Жыл бұрын

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 Жыл бұрын

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.

@andreamarrucci7488 2 жыл бұрын

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!

@bryanwoodhead6490 2 жыл бұрын

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 2 жыл бұрын

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

@jamesdahmer5027 Жыл бұрын

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!

@daneast Жыл бұрын

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 Жыл бұрын

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 7 ай бұрын

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

@ericfgj Жыл бұрын

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 Жыл бұрын

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

@hebdomatical 2 жыл бұрын

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 2 жыл бұрын

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!

@edwinmontes6588 Жыл бұрын

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

@FabbinAdventures Жыл бұрын

No, i have no idea, sorry

@allengonzalez3253 2 жыл бұрын

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

@FabbinAdventures 2 жыл бұрын

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

@CaptainGSR Жыл бұрын

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 Жыл бұрын

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.

@jaymurray5790 Жыл бұрын

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 Жыл бұрын

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

@shanahardy5228 Жыл бұрын

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

@FabbinAdventures Жыл бұрын

Nope, tranny will have to come out.

@user-ed8gg7yy8b 7 ай бұрын

Does the Tracker have the same transmission?

@FabbinAdventures 7 ай бұрын

It is different, sorry

@beekeeper7535 Жыл бұрын

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 Жыл бұрын

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

@samikhattak2589 2 жыл бұрын

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

@FabbinAdventures 2 жыл бұрын

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

@xXZ31t6esTXx 3 жыл бұрын

Prelup the bearings with what?

@FabbinAdventures 3 жыл бұрын

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

@user-yu7ye8bm9y 10 ай бұрын

inside is very similar to JA11,JA22 trans.

@richardsingh6014 2 жыл бұрын

Did you replace the extension case bushing?

@FabbinAdventures 2 жыл бұрын

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

@richardsingh6014 2 жыл бұрын

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

@FabbinAdventures 2 жыл бұрын

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

@austinwise9987 Жыл бұрын

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 Жыл бұрын

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

@austinwise9987 Жыл бұрын

@@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 Жыл бұрын

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.

@austinwise9987 Жыл бұрын

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

@FabbinAdventures Жыл бұрын

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

@birimrachacheranmomin3540 2 жыл бұрын

So there's six bearings inside the transmission right?

@FabbinAdventures 2 жыл бұрын

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

@birimrachacheranmomin3540 2 жыл бұрын

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

@FabbinAdventures 2 жыл бұрын

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

@birimrachacheranmomin3540 2 жыл бұрын

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

@FabbinAdventures 2 жыл бұрын

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

@ARLI919 3 жыл бұрын

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

@FabbinAdventures 3 жыл бұрын

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

@harleystewart4344 4 жыл бұрын

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 4 жыл бұрын

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 Жыл бұрын

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 Жыл бұрын

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.

@mauriciocastro2347 4 жыл бұрын

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 4 жыл бұрын

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 4 жыл бұрын

Thanks!!!!

@zazazizo6958 Жыл бұрын

Pajro

@joelgraba1077 3 жыл бұрын

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

@FabbinAdventures 3 жыл бұрын

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

@codyswilley 4 жыл бұрын

First

@FabbinAdventures 4 жыл бұрын

Damn your quick!

@codyswilley 4 жыл бұрын

@@FabbinAdventures gotta be quick lol.

@suzysuzuki8865 2 жыл бұрын

Could I get away with doing this without a press?

@FabbinAdventures 2 жыл бұрын

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 3 жыл бұрын

chi-com bearings-done-fail-out!

@FabbinAdventures 3 жыл бұрын

Yup they were shot! Thanks for watching!

@horacerumpole6912 3 жыл бұрын

@@FabbinAdventures Referring to the new ones-

@shtfvan8084 2 жыл бұрын

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 2 жыл бұрын

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!