Changing out the ring |removethispart|@ pinion gears to 4.57 on a 94 sammy.  I got 1 kit from Las Vegas drivetrain and I found that the rebuld parts all seemed just a little bit wrong.  Crush sleeve dia was incorrect (too small) pinion seal was loose on shaft (would leak for sure) and the splines on the new pinion were cut just different enough to cause a 12 ton press to stall.  A 94 has slightly larger flanges for the driveshaft as well as a different diff in the front 3rd.

Is it possible that on a 94 the mensioned parts are just a little different?

I just got a Yukon kit but I can see the seal is inccorect I'll be checking the rest tonight.

Any ideas??

Was this on the front diff or the rear?

This is the case on the front and rear.  I got gears from Yukon last night and the seals, crush sleeve and bearings are ok but the splines on the pinion are still incorrect.  beasically I have to press the splines through the yoke and cut the new shape into it.  Scarry but what else can I do.  I feel the Yukon gears are made in Tiwan they look identical (markings and everything) to the other gears I had that did have on the box made in tiwan.

Supposedly they changed the diff housing at some point in the Samurai life-line but I don't know what the differences are.   Since you have a 94 it's one of the last ones produced.

If you get a set of third members from an earlier samurai and just swap your flange over it may resolve the issue.  I would try giving Hawk Suzuki a call, they should be able to set you straight.

Changing out the ring |removethispart||removethispart|@ pinion gears to 4.57 on a 94 sammy.  I got 1 kit from Las Vegas drivetrain and I found that the rebuld parts all seemed just a little bit wrong.  Crush sleeve dia was incorrect (too small) pinion seal was loose on shaft (would leak for sure) and the splines on the new pinion were cut just different enough to cause a 12 ton press to stall.  A 94 has slightly larger flanges for the driveshaft as well as a different diff in the front 3rd.

Is it possible that on a 94 the mensioned parts are just a little different?

I just got a Yukon kit but I can see the seal is inccorect I'll be checking the rest tonight.

Any ideas??

The pinion seals are the same for all samurais (86-95).  And as far as I know, all use the same crush sleeve.  I'd say they sent you the wrong rebuild kit.
There are 2 different types of splines used on samurai pinions (and trackick pinions, for that matter).  They are the same count, just cut differently.  See the following link, it shows what I am talking about.
http://bbs.zuwharrie.com/content/topic,55582.0.html
Note that I refer to "new" and "old" splines in the link....I don't think it has anything to do with new and old.
Yes, the diameter of the pinion flanges are larger on the later samurais (88.5-95).  They are larger, because the driveshaft flange bolt pattern is larger.
The carrier in the later samurais (88.5-95) are also different from the earlier ones.  The carrier itself is shaped differently and only contain 2 spider gears and a single crosspin, versus the 4 spidergears and 3 crosspins of the early samurais (86-88).

Thanks a lot for the info.  I wish Yukon would realize that this is a problem before they claim the R & P fits to 95.  By the way the single pin diff is only present on the front axle. 

Sounds like finding old flanges would help me but then my driveshafts won't fit.  I already succuessfully pressed an old pinion thru a new flange to cut the new splines into the right shape.  Scarry I know but if the flanges are not any good I guess the worst thing that could happen is these new comprimised splines in the hub would strip out.

At leat I know what the deal is now Thanks a lot.

Thanks a lot for the info.  I wish Yukon would realize that this is a problem before they claim the R & P fits to 95.  By the way the single pin diff is only present on the front axle. 

Sounds like finding old flanges would help me but then my driveshafts won't fit.  I already succuessfully pressed an old pinion thru a new flange to cut the new splines into the right shape.  Scarry I know but if the flanges are not any good I guess the worst thing that could happen is these new comprimised splines in the hub would strip out.

At leat I know what the deal is now Thanks a lot.

Yes, I should have specified that the single pin carrier only applies to the later front axles.  All rear carriers are the 3 pin type.
And it is not a "new flange" vs. "old flange" difference, like I thought when I first posted that thread....the different splines can be found on about any year samurai.
89-98 (and maybe later) trackick pinion flanges will interchange with samurai ones (and all trackick flanges have the larger bolt pattern that matches your driveshafts).  And they have the two different types of splines as well, like the samurais.  So if you could find a pair of trackick flanges (either with or without the ring around the outside of the flange..whichever type you need), you could use those on the yukon gears and your driveshafts will bolt right up to them.
I would not mix the two different types of splines.....especially the ones that you have to use a big press to get the flange to fit the pinion.  Yes, they could strip the splines and if they do it will probably damage the pinion splines and ruin the pinion.  And I am sure yukon won't warranty them, if that happens.  So you'll be buying another new set of gears.
So I am guessing the pinions have the "pointy" splines and your flanges have the "squared" splines, right?

You are right.  I have the larger flange with the non-pointey splines.  So how the |removethispart|@$#& can I make sure I get a large flange with the pointey splines?  I did get a brand new flange from the dealer and it did not have the pointy splines.  I'll check with them to see if I can find a large flange with the other type of splines.

I still think when I pressed the new pinion into the hub that the hub was cut pretty close to what it needs.  But you never know I guess.  FYI the hub can't hurt the pinion.  The pinion is made for very hard steel while the

You are right.  I have the larger flange with the non-pointey splines.  So how the |removethispart||removethispart|@$#& can I make sure I get a large flange with the pointey splines?  I did get a brand new flange from the dealer and it did not have the pointy splines.  I'll check with them to see if I can find a large flange with the other type of splines.

I still think when I pressed the new pinion into the hub that the hub was cut pretty close to what it needs.  But you never know I guess.  FYI the hub can't hurt the pinion.  The pinion is made for very hard steel while the

If you are ordering flanges from somewhere, I don't know how you can make sure you get one with the right spline type....maybe try ordering one for an 89 samurai....it should have the large pattern for the driveshaft and might have a better chance of having the pointy splines.  If you are buying one from someone, where they can look at the flange, before you buy it....they can look at the splines, and/or they can look at the perimeter of the flange, to see if it has a ring/groove around it or not (look at the linked post again, if you don't understand).  To match the new pinion, you will need a flange with pointy splines (so it will NOT have the ring/groove around the perimeter of the flange).
I would suspect the pinion and the flange splines are pretty close in their hardness.  But if you think it is ok, go ahead and press them on and run them.  I wouldn't, but that's just me.

I'll check with the dealer and see if there is another large flange part number than the one I ordered before the difference would have to be the splines (probably why the needed the VIN for the order).  If not I'll just press them in but I hate doing things like that.

I am sure abou the hardness.  The pinion is made from 80.. series steel to provide the strength for the gear teeth the flange is cast and machined.

I'll let you know what I find out from the dealer tonight.

Thanks...   I have the same problem with my timing belt damn teeth where a little different (also by VIN).  I guess in 94 they started to use some of the trackkick parts to make it easier for them.

On yours, the timing belt teeth were probably rounded, instead of squared, right?  I don't know if the cam pulley will interchange with a trackick (I think it will)....but I know the timing belt itself is different length between the samurais and trackicks...so they wouldn't be able to use that part on both engines.
Also, if you notice, you should have a 5 bolt crank pulley, vs. the 4 bolt found on earlier samurais.  You still have V-belts though, don't you?  Instead of the ribbed type belts that were used on all 1.6 trackicks.

You're right on the timing belt.  They do make one so I have it I just got the wrong one first.

On the splines for the flanges I went to the dealer and they only have new version splines with the large flange actually replaces the large flange with the pointed splines.  The pointed splines are only available with the old small flange.  The P/N is there but they don;t have what I need.  It's as I suspected...the flange that I have is the sidekik version.  So they used all the pointed splines up and switched over to the sidekik mid year.  I pressed the pinions thru on the weekend and they really look pretty good.  I hope they don't strip out.