ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Technical Discussion - Performance / Modify => Topic started by: perkins1006 on July 15, 2015, 12:12:02 PM
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Has anyone done a 1.6 16v swap in a Samurai without using a adapter plate?
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You will need to use a 1600cc Tracker/Sidekick transmission in order to do so. However, it does allow one to keep the larger and heavier 1600cc flywheel, which results in better low end torque.
Please be aware there is quite a bit more work involved, such as cutting a new shifter hole, shortening the intermediate shaft, fabbing up a new rear crossmember mount, etc. You can use a 4WD or 2WD tranny, but the 4WD tranny will need the married transfer case removed, and an output seal adapter installed. If you use a 4-speed auto, you will also need to wire in the tranny computer. In contrast, if you use the 1600cc adapter kit with the manual Samurai transmission, it is a bolt together affair.
FYI, another option existed around 10 years ago when two different fabricators sold a machined kit that allowed the 1600cc trans, transfer, and Samurai transfer to be used as one unit. It was called the Kicker 3, as well as other names.
(http://www.pirate4x4.com/forum/attachments/miscellaneous/83858d1063655885-samurai-has-been-married-kicker-three-cutout.jpg)
(http://i10.photobucket.com/albums/a102/rockfab/RockReductionBox028.jpg)
Basically, the front output of the Sidekick/Tracker transfer case was cutoff, the corresponding internals removed, and the remaining hole covered and welded shut. This allowed the Sidekick transfer to be used a simply a 1:1/1:1.8 aka a doubler. Combine that with a Samurai 4.1:1 case, and one had a 7.38:1 low range. However, there was sometimes an issue with the slight misalignment of the two transfer cases, hardness reliability issues with the coupler (a cut down driveshaft splined section), and it seemed like a real pain in the neck to service/repair.
Since that time, low cost 6.5:1 t-case gears have hit the market, which are easy to install and seem to be quite reliable. Hence, the Kicker 3 has largely been forgotten.
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I've heard of it being done by welding & redrilling the bell housing.
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That was before the bolt-on adapter kit, circa 1995. Been there, done that, and even made a write up nearly 20 years ago on the old Off-Road.com BBS. That install still used a sheetmetal "gasket" much like the stock piece, but larger for the 1600cc engine. This gasket also served as the template for cutting & welding on the tabs onto the transmission. There is a reason why that method is not used anymore. ;)
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I to heard of drilling the bottom gearbox bolt holes into the block and using the tracker gearbox bolts as they are larger than the stock Samaria
Sounds like the Adapter plate is the way to go.
Picking up a 1995 sidekick as a donor so now i am putting together a list of parts to order. Hoping to save $150 on a adapter plate.
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Go ahead and spend the $150 or find one used. It is money well spent.
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an adapter plate is definitely the way to go, it makes the swap too easy.
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Thanks everyone.
I like the look of the Trail Tough one.
Just took delivery of my donor today so i guess i need to order one soon.