Hi all , I just became the proud owner of a 91 samurai , Its a 2wd lowered on 225/50's with 15x10 rims. .. Thats not what I want , I also got both front and rear 4wd axles, transfer case from an 89 samurai, the motor in the 91 is froze up..but I also got a 91 1.6 tracker motor with tranny and transfer case. I want to do a spoa lift and 3" body lift and swap in the tracker motor, can I use the motor,tranny,and transfer case , and how hard will it be? Im new to Suzuki's but not to fabrication.
Thanks Tony

I also got a 91 1.6 tracker motor with tranny and transfer case. I want to do a spoa lift and 3" body lift and swap in the tracker motor, can I use the motor,tranny,and transfer case , and how hard will it be?
Thanks Tony

Easiest way to fit the 1.6 is to use an adapter plate and bolt it up to the 1.3 gearbox. If you can fab then you can get by without the plate. Either two weld tabs to the gearbox or make up some 'adapter bolts'. If you google Nitromax Suzuki you will find a good article, there are others too.

ok Im pullin out the 1.3 today , Do i need to use the clutch and pressur plate from the 1.3 to the 1.6? to fit into the 1.3 tranny? also do I need to swap everything onto the 1.6 like intake,exaust manifolds? I know i need the 1.3 distrubutor and an upgraded fuel pump or is that just for the 1.6 carb?
Tony

ok Im pullin out the 1.3 today , Do i need to use the clutch and pressur plate from the 1.3 to the 1.6? to fit into the 1.3 tranny? also do I need to swap everything onto the 1.6 like intake,exaust manifolds? I know i need the 1.3 distrubutor and an upgraded fuel pump or is that just for the 1.6 carb?
Tony

Let me try and help a bit. From the list of parts you stated, I'd suggest: Buying one of the 1.6 to 1.3 adapter kits. Pull the intake (the whole shabang), distributor, flywheel, pressure plate, clutch, and exhaust off of the 1.3. Put all of that on the 1.6 long block, bolt on the adapter kit, bolt that to your Samurai transmission.  Put that in the Samurai, put your '89 4wd driveshafts, t-case, and front differential in. The rear differentials are identical.

Ok, that parts done....

Now, you've got a running driving Samurai to begin your off-road mods on...

Good luck, Eric

Oh yeah one more thing.    A spring over lift AND a body lift is a lot of lift. A 32" tire can fit a SPOA set up pretty comfortable and that is just about all the stock Suzuki axles can take.

-Eric

Ok thanks for the info, I should have it running in a week or so, .. I guess I should start shopping for some axles cause I want to put 35's on it, I have 31's now but want a little bigger, again thanks for the help.  Oh one more ? what about the starter?  I need one for the 1.6? or will the 1.3 work?

Like I said Im new to zukis , I was planning 3" lift springs with traction bars, 2" shackles, spring over lift,and 3" body lift.. with 35" boggers, It kinda sounds like a death trap huh, You guys are the exprerienced ones on here what do you think, If I need bigger axles what do I start with? Full size chevy 1/4 ton? then I guess Id have to shorten them , ... I guess Ill start reading more on the forum. Ive been on here non-stop since I got the thang and I guess when I get it rollin Ill be hooked. 

Like I said Im new to zukis , I was planning 3" lift springs with traction bars, 2" shackles, spring over lift,and 3" body lift.. with 35" boggers, It kinda sounds like a death trap huh, You guys are the exprerienced ones on here what do you think, If I need bigger axles what do I start with? Full size chevy 1/4 ton? then I guess Id have to shorten them , ... I guess Ill start reading more on the forum. Ive been on here non-stop since I got the thang and I guess when I get it rollin Ill be hooked. 

Either starter will work the 1.6 starter is better. If you already have some 31 inch tires I'd say do a basic SPOA and run those for awhile. Honestly, you should be able to go just about anywhere you want to go. Of course, I don't know your terrain or the crowd your hanging with but in general that is a very popular size to make a capable rig. One thing to think about is the ratios for everything. Such as a Samurai has the same if not better diff clearance with a 30" tall tire than a D44 with a 33" tall tire. Plus it is offset so that it doesn't hit the center mound of the two ruts your driving in.

I'd suggest building it small first... enjoy it for awhile... and then see if you want to go really big(ger).

HTH -Eric

Does the 1.3 dist. fit into the 1.6 dist. mount on the back of the head or do I need to swap the whole mount?
Tony

If you ever do decide to run bigger tires and you want to go bigger. you could go for toyota axles. sky manufacturing makes a off set yota axles and there about 375 with the short side axle, no 3rd .
Oh yeah if your going to put some 33's on your sammie, you gotta think about gears to. the 33's might be a little hard on the clutch if ya know what i mean.
good luck, keep us posted with loads of pics and info about what your doing.
Millski

never mind I had to change the whole mount . The 1.3 dist dosent fit into the 1.6 housing the end is too big to fit in the hole.. I never thought I would say that... LOL  swapped the housing and got the rotor pointed at # 1 . after I got the engine to TDC , I hope I got everything right.... I just have to solder a few wires on the harnes ,figure out some too , If I send a pic can someone tell me where these wires go? I think they go to the tranny and transfer case? but the plug is different. All I have to work with is the Haynes and it pretty much dosent show what goes where?? I still need to clean out the gas tank Its been sitting for 3 yrs and Im sure its nasty, .. Can I use the electric fuel pump in the 91 with and older carb from an 88? cause the 1.6 dosent have a mech fuel pump?? Im not even sure where all these hoses go......
Tony

never mind I had to change the whole mount . The 1.3 dist dosent fit into the 1.6 housing the end is too big to fit in the hole.. I never thought I would say that... LOL  swapped the housing and got the rotor pointed at # 1 . after I got the engine to TDC , I hope I got everything right.... I just have to solder a few wires on the harnes ,figure out some too , If I send a pic can someone tell me where these wires go? I think they go to the tranny and transfer case? but the plug is different. All I have to work with is the Haynes and it pretty much dosent show what goes where?? I still need to clean out the gas tank Its been sitting for 3 yrs and Im sure its nasty, .. Can I use the electric fuel pump in the 91 with and older carb from an 88? cause the 1.6 dosent have a mech fuel pump?? Im not even sure where all these hoses go......
Tony

You will need a low pressure pump, so if the 91 is EFI then no.
I am in the middle of fitting a 1.6 into my SJ413, but I have a carb 1.6 which has a mechanical fuel pump so no problems there, except for a small bit of clearancing on the inlet manifold.
If you're going SPOA then you should be able to run with the 1.6 oil pan OK.
I have swapped the main water gallery from the 1.3 to the 1.6 to make connecting up the hoses easier, you need to remove the tag from the end of the gallery that goes into the back of the water pump.
I used the 1.3 inlet manifold and opened up the ports to suit the 1.6 head, you need to be a bit careful there as there is an oilway that you need to work round.
Surprisingly although the exhaust ports are bigger on the 1.6 the manifold matches up almost perfectly - pity mine is cracked.
I'm told that you need to swap the temperature sensor for the water temp gauge as they are different values.
I haven't tried fitting the dizzy yet, I guess I shall have to swap the mount too.
I have an adapter plate but need to source the stock engine/box plate as that is needed as well.
One engine mount needs to be sorted, there are specially made mounts or the standard mount can be cut off and rewelded in the right place, alternatively I have someone simply rotate the stock mount 90 degs to get it to line up.
You may need a 'power bulge' in the bonnet to clear the carb as the engine is around 1/2" taller.

Theres probably other stuff too.