Hey guys,
After shooting my mouth off about "how hard could it be to rebuild one" I've started to wonder just how hard it really is to rebuild my 86 Samurai transmission. Has anyone rebuilt one here? What special tools are required if any? Would you do it again? I have check out eBay for a used tranny... I found one that is from a 1988 1/2 that looks clean... I know that doesn't indicate anything as to it's condition, but it still looks like a nice one.

As always... any help is very much appreciated
Dennis

I have personally rebuilt like 6 of them, and for the price of a bearing kit, or gear set, it is worth the time. it was one of the easiest things i have ever done with the sammy.....  check out www.samuraiparts.com for the bearing kits, if that is what it is needing. due to howling, whining etc. i recommend rebuilding it yourself, and not only for the cost, but for the experience too! if u have any questions, i might be able to find a how to video i made on rebuilding them....  might not have it on here ne more tho.. let me know, i can probably walk/talk/message u through it!

blknight87,
Thanks for the reply and the offer to help me out. I just finished draining the oil from the transmission...it looked very clean with no metal flakes of any kind. I will refill it tomorrow and test drive it to try to determine for sure if it is the tranny that is making the noise. I hear it in all gears and even in neutral while coasting. I've read about guys here hearing noises in one gear or another but mine is in all gears... could this indicate that it's a main bearing that has gone south?. The noise is a very noticeable loud grumbling metal to metal grinding sound, it feels like something is about to let go. Any ideas as to what it could be and how to test for it?  It does shift very smoothly in all of it's gears... Could it be anything to do with the clutch? I feel like I am grasping at straws here.

Thanks,
Dennis

I would check out your t case sami cases are very noisy even when they are good, if you have access to a stethascope I would try driving while moving it along the tunnel you should be able to decipher pretty easily a piece of hose will work but you may need a third hand to hold it to your ear

Thanks I'll give that a try.

Dennis

I just finished road testing my Samurai after rebuilding/replacing a ton of front end parts... The noise is still very much present. I had a local mechanic drive with me around for 10 minutes and he thinks it's a bearing in the transmission.  As I reported earlier the trans oil when I drained it was very clean with no metal particles of any kind and it shifts like silk. The sound is present in all 5 gears and in neutral while moving... also in 4wd high and low. If it is a main end bearing that is bad could I get away with just replacing it if all others are fine? I kinda remember reading somewhere that that would be a acceptable practice if no bearing metal is found in the oil. Any thoughts?

Dennis

Stick the transfer case in neutral and shift thru all the gears with the engine on. That might tell you if some or all the noise is coming from the transmission. I rebuilt mine and a couple others using pullers, bearing separators  and a cheap Harbor freight press and a few odds and ends. It helps to have a transmission as a model in case the pictures confuse you. Just lay the parts out in order as you remove them and take your time. Just be extremely careful as you do it so you keep the parts in the right order. First ones the most difficult but if the transmission is truly noisy, you may as well renew the whole transmission. The money you save rebuilding your own will easily pay for any new tools you buy providing you're successful I think minimum, you can do it with a brass hammer (just to not distort anything), Long pullers, and the bearing separator but it sure is easier with the press.

-Adam

Daddyizzle,

Thanks for the information and the words of encouragement. I will try the transfer case in neutral while shifting with engine running.

Thanks again,
Dennis

Yeah my guess is the bearings! No way to test but to pull and open to inspect. Sounds just like all the ones I've rebuilt.

Blacknght87,

I have ordered a transmission bearing kit and a new clutch assembly, Can you recommend anything else I should replace/do to the Samurai while I have the tranny out? I've never preformed this particular surgery before so I am kinda shooting in the dark. I am sure it will all make sense once I get going. 

Thanks 

How's your clutch? Might check into replacing that too. The rebuild is easy, take the tail housing off, then unbolt the input shaft bearing cover, then the bolts all around the top, and don't forget the bolt by the shifter for the shift rods! Pry apart, and the rest is simple! Lemme know if u need be more help ill be home in like 3 days.