ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Suzuki 4x4 Forum => Topic started by: cyborgben on November 26, 2006, 07:52:38 PM
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Replacing the clutch in an 87 Samurai - removed shaft, exhaust, etc. Found rear crossmember is factory-welded in place. No bolt holes..... How do I get the transmission out so I can replace the clutch?
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I pulled the 4 motor mount bolts and slid the engine 1 inch forward. remember to pull the shifter
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Thank you.....
I've heard that the Samurai clutch is "easy"....is this really the only way, or can it be done leaving the trans. in place? Thanks in advance....
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remember to unplug the 2 switches on the top of tranny
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I don't remember mine being factory welded. I will have to climb under my new one and look. My 87 softtop just had the bolts at the back under the rear of the tranny. I think 4, and the bell housing. I never had to unbolt the motor mounts. ?????????????
My 87 was a piece of cake to change a clutch. Except the exaust bolts going into the manifold were previously crossthreaded and I had to rethread. I think they were 10x1.25. metric of course.
-Adam
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Yes...my tranny does have 4 bolts at the back, that are bolted to a bracket, that is bolted to a welded-in crossmember. the bracket came out easily, but I'm about an inch short of space.
thank goodness the engine is a small one!
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I pulled mine by myself, no jack underneath it. It sucked having to hold it with one hand and pry the engine forward to get enough clearance for it to drop out. I never unbolted my engine but that may have helped. Just make sure you put a piece of wood between the firewall and distributor housing to protect it. After fighting with the tranny I then read later that guys notch their crossmember a bit for extra clearance.
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thanks much....I hadn't thought of the notching idea....
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I gave it some more thought. It all came back. I did have to lift up on the engine a little. I think I had a broken motor mount at the time so it had some give. It wasn't a great deal. I remember having a piece of strap supporting the tranny from above just enough to allow me to manipulate it into position while I lined it up with the spline. It was one of those tie down straps and I ran it through the cab and under the vehicle . I jacked the tranny with a floor jack and slipped the strap underneath so I could swing it around without the jack being in the way. You need to have it in 1st gear so you can turn the back of it to make the front turn and line up. At least that's what I did to make it easier. I'm not an expert on this but that's what worked for me. Maybe someone here has a better technique?
-Adam
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i just loosen the motor mounts and shove the tranny in by hand. its light enough i do it by hand. by i know of guys that make the crossmember revoveable. and would like some pictures
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Cy,
When I did my 88 I pulled the shifter out then removed the bolts between the engine and transmission. i put a jack under the engine to lift it up a little to clear the transmission. I then notched the crossmember pushed the transmission back as far as I could (making sure it was disconnected from the engine with the shaft) then jacked up the engine tilted the transmission down and slide it out. Not knowing how strong you are, I am able to bench 300+ pounds so the 70 lbs transmission was a one handed manuver. I went this route because getting two jacks under the samurai with me being 270 lbs myself is a bit of a trick.
When you are putting it back in make sure you make the engine is level with the transmission took me a while to figure that one out. (DUH)
Hope this helps a little.
Bash
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well its done. just looseened the motor, slid it foreward and was done. no prying, or jacking, or possibly damaging the new clutch on the way in. I do think it could be done in a pinch leaving the tranny in and working in the 5" space created. Yeh, the 1hand bench while turning the shaft to line up the splines is possible ( |removethispart|@ 225 with a near 400 bench this may not be possible for everyone but wasn't to bad for me.) Thanks for everyones help, my $250 junkyard tintop my be on the road soon.
ben
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I need to know where this junk yard is!
-Adam
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in PA, a long way from Arkansas. just a small yard where i've become a regular. anything odd (meaning non gm, ford etc)goes for cheap. When i bought it with 90k the clutch was out, i started it and let it idle in the yard for about 10min, and the frame is totally rust-free with the original blue paint all over, body a little dented, surface rusted from neglect as a farm vehicle. I also bought a volvo 740 turbo wagon with perfect heated black leather interior the same day for $250 also. 2 cool vehicles, 1 day, $500.....priceless.
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130 and ,Maybe, 150 bench. the one handed lift and twist the shaft is probably possible for everyone.