Hey guys , Im in the process of converting a 91 samurai into 4wd and the transfer case I have is from a 87? It worked fine when they parked it about 15 yrs ago and now its froze up. I thought it was the bushing so I got one from rocky road.. That didnt do it. Upon futher inspection I found both fill hole bolts loose and Its seams to be dry inside, Is there something I can pour into it to free it up and maybe loosen it up or do I need to rebuild it? Ive never rebuilt one and the haynes manual says ONLY A PROFESSIONAL should attempt it? What to do I really dont have the cash to have it rebuilt but I have plenty of time.

The only thing that can keep you from rebuilding that t-case is the cost of any tools that you may buy, the rebuild kit and your desire to learn something new.

Go for it!


On another note, the flanges on that '87 will not match the rest of the '91 truck (at least the rear driveshaft in your case) because the flange size changed during the great '88.5 model year or thereabouts.  That's not the end of the world, though.  You can find flanges in the junkyard that will probably work fine.  It would be helpful to find an '87 intermediate shaft to cut down on the flange replacement situation.


Good luck!

Ok good news the transfer case isnt shot! I filled it up with gear lube and it still wouldnt shift then I read somewhere I need to make sure the inside gears were line up ..Thats what it was, Lined up the two shafts installed the RRO shaft bushing and BAM it works . Now all I have to do is figure out all this wiring for the 1.6 swap
Tony

hello
theres nothing to it just watch as you take it apart and the ball bearing that sets in where the shifter rod goes in it about the hardest part of it but other than that its easy and after you have done it a time or 2 its easy.
thanks rick.