INSTALL INSTRUCTIONS

TRAIL-CREEPER SUZUKI SAMURAI I-CASE GEARS

303760-3-KJT 1986-1995 SUZUKI SAMURAI 4WD (4.16:1)
303761-3-KIT 1986-1995 SUZUKI SAMURAI 4WD (4.90:1)
105004-3-KIT 1986-1995 SUZUKI SAMURAI 4WD (6.50:1)
303924-3-KIT SUZUKI JIMMY JA11./.JA11,/.JA71 (4.16:1)
303925-3-KIT SUZUKI JIMMY JA11./.JA11,/.JA71 (4.90:1)

KIT CONTENTS

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Part Number: 105004-3-KIT Part Number: 303760-3-KIT & 303761-3-KIT

Part Number: 303924-3-KIT & 303925-3-KIT

105004-3-INS
INSTALL INSTRUCTIONS (COMT'D.J
RECOMMENDED TOO LS
Screwdriver Wheel Bearing Grease

Ball Peen Hammer Ultra Grey RTV Silicone

Rubber Mallet Razor Blade or Gasket Scraper

Safety Glasses Degreasing Compound (e.g. Brake Cleaner)

Metric Ratchet & Socket Set Torque Wrench

Metric Wrench Set Allen Wrench Set

3/16" Pin Punch Adjustable Wrench

Die Grinder API GLS SAE 75W-90 Gear Oil (Approx. 1 quart)

Snap Ring Pliers Transmission Jack

Arbor Press Needle Nose Pliers

CAUTION
1. Read all instructions completely and carefully before you begin.

2. Check to make sure the kit is complete and that no parts are missing (refer to the Kit
Contents Section on the first page of these instructions).

3. Park vehicle on a clean, dry, flat, level surface and block the tires so the vehicle cannot
roll in either direction.

4. T his product is for off-road use only. It is recommended that the installation steps below
be performed by a competent mechanic. Buyers and users of this product hereby expressly
assume all risks associated with the installation and use of this product.

5. This installation is typical for most Suzuki Samurai vehicles. Some vehicles may vary. If
necessary, refer to the proper Factory Service Manual for the year and model of your vehi­
cle.

ACAUTION

6
Flying Object Hazard.
Fluid Splash Hazard.
Wtat
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INSTALL INSTRUCTIONS (CONT'D.)
In these instructions, we refer to the different transfer case housing sections by name. The photo below shows each of the
housing and it's name.

Front Hou5ing

Rear Housing Center Housing

STEP 1 SiEP 2
Loosen and remove the (4) bolts and nuts from each Remove the clamp and boot from the transfer case.
of the (3) driveline flanges on the transfer case. Save Save for reinstallation.
the (12) bolts and nuts from the transfer case.

TRANSFER CASE

STEP 3 STEP 4
Remove the control lever from the transfer case by twisting Remove the transfer case drain plug and drain the oil.
the control lever guide counterclockwise while pushing it Discard the used oil in accordance with all local laws. Many
down. Save for reinstallation. auto parts stores will accept used oil for little or no cost.
Save the drain plug for reinstallation.
/
-_/

•
NOTICE
Dispose of
used gear oil in
accordance
with all local
laws.
INSTALL IMSTRUCT!OMS (CONT'D.,)
STEP 5 STEP &
Disconnect the speedometer drive cable from the transfer Disconnect the 4WD position switch electrical plug.
case.

STEP 7
Place a transmission jack under the transfer case. Loosen and remove the (3) nuts securing the transfer case to the
chassis. Save the (3) nuts for reinstallation. Remove the transfer case from the vehicle. Make sure all mounting
brackets and crossmembers have been removed from the transfer case.

STEP e STEP 9
Remove the 4wd indicator light using a 21 mm Turn the transfer case over and collect the 4wd indicator
wrench. ball as it falls out of the hole for the 4wd
indicator. This steel ball is larger than the other
two balls removed later.

STEP 10 STEP 11
Using a 1 1/6" or 28mm socket, remove all three Notice that the rear output flange is different than
flange nuts and the flanges. A bearing puller may the front output and input flanges.
be needed to pull the flanges off.

/
Front Output I Input

STEP 12 STEP 13
On the bottom of the transfer case, remove the detent Remove the detent spring using a small screwdriver
plug using a 6 mm alien wrench. or punch. Flip the case over and remove the
detent ball.
INSTALL IMSTRUCT!OMS (CONT'D.,)
STEP 14 STEP 15
Remove the speedometer output bolt. Remove the speedometer output.
------

�TEP 16 �TEP 17
Remove the 7 bolts holding the front housing on. Remove the front housing.
Note the position of each bolt and return each bolt
to the same position when reassembling.

�TEP 18 �TEP 19
Remove the lock tab and bo lt that holds the Remove the eleven (11) bolts holding the center
counter shaft. and rear housings together.
INSTALL INSTRUCTIONS (CONT'D.,)
STEP 20 STEP 21
Using a small hammer, tap the center and rear As the cases come apart, be sure to catch the steel
housing cases apart. ball. This ball will be reinstalled near the end. It
may be necessary to tap lightly on the housing to
dislodge the ball.

STEP 22 SiEP 23
Remove the counter shaft gear and shim from the Remove the input gear and bearing assembly.
rear housing.

STEP 24 SiEP 25
Remove the counter shaft, bearings and shim. Remove the shift fork assembly as shown.
INSTALL IMSTRUCT!OMS (CONT'D.,)
STEP 26 �YEP 27
Remove the output gear assembly from the rear Remove the snap ring from the end of the output
housing. Hold the rear housing and press down on
the housing to dislodge the output. It may be
necessary to lift and drop the housing on a flat
surface to get it apart.

STEP ze STEP Z9
Remove the gear as shown. Using a press, press the output gear through the
bearing as shown.

STEP 30 STEP 31
Remove the output bearing. Remove the spacer from the low output gear.
INSTALL INSTRUCTIONS (CONT'D.,)
STEP 3Z STEP 33
Remove the hiah soeed outout aear. Remove the needle bearing assembly from the
shaft.

STEP 34 STEP 35
Remove the shift collar. Turn the gear assembly upside down and press the
output shaft through the low speed gear.

STEP 3$ STEP 37
Remove the bearing keeper. Remove the bearing.
INSTALL INSTRUCTIONS (CONT'D.,)
STEP 38 STEP 39
Remove the drive gear. Remove the shim.

STEP 40 STEP 41
Remove the low speed gear. Remove the cage bearing. Clean the cage bearings,
shafts and housings.

STEP 4l STEP 43
Reinstall the cage bearing on the output shaft. Install the new low speed gear onto the output
shaft.
INSTALL IMSTRUCT!OMS (CONT'D.,)
STEP 44 STEP 45
Reinstall the spacer. Reinstall the drive gear.

STEP 46 STEP 47
Using a piece of tubing, press or hammer the drive Reinstall the bearing onto the shaft.
gear down onto the shaft.

STEP 48 STEP 49
Press the bearing into place. Reinstall the collar.
STEP 50 STEP 51
Press the collar into place. Flip over the output shaft to assemble the other
side. Slide the shift collar into place.

STEP 52 STEP 53
Reinstall the bearing onto the shaft. Apply grease to the bearing.

STEP 54 STEP 55
Install the new high speed output gear. Reinstall the shim.
INSTALL IMSTRUCT!OMS (CONT'D.,)
STEP 56 $TEP 57
Reinstall the bearing and press it into place. Install the gear as shown.

SiEP se STEP 59
Reinstall the snap ring. Using a press, remove the bearings from both ends
of the input shaft.

STEP 60 STEP $1
A socket that is smaller then the shaft size works Once the first bearing is removed, flip the gear
well for pressing out the bearings. We suggest a over to press off the second bearing.
14mm, 3/8" drive socket.
INSTALL INSTRUCTIONS (CONT'D.,)
STEP 62 �YEP 63
Strips of 1/4 plate steel work well for getting in
• Discard the original input shaft. The new input
between the input gear and the bearing on the shaft is shown above.
drive flange end of the shaft.

STEP 64 SiEP 65
Reinstall the bearing on the end of the shaft as Using a socket and press or hammer, press bearing
shown. into place.

STEP 66 SiEP 67
Install the bearing on the other side of the input Temporarily install the new counter shaft, counter
shaft and press the bearing into place. shaft gear and bearings. Look for the gear rubbing
at the points above.
STEP 68 �YEP 69
Grind as needed with a Dremel® rotary tool to Both sides of the case may need to be clearanced.
prevent gear interference with the case. Spin the gear in place to ensure that it des not
,..-,..-,..- grind on the case. Remove the counter shaft and
gear when grinding is complete.

STEP 70 STEP 71
Remove and inspect the shifter seat. Check to see that there are no cracks or missing
material. If there is any sign of wear, replace the
seat with a new one.

STEP 71. STEP 73

Remove the old rear output seal from the rear Install the new rear seal provided with the kit.
housing.
STEP 74 SYEP 75
Remove the old front input seal. Install the new front input seal provided with the
kit.

STEP 76 SiEP 77
Remove the old front output seal. Install the new front output seal provided in the
kit.

STEP i'8 STEP 79

Install the steel ball in the center housing as shown Adjust the shift rail until the ball drops into the slot
above. This is the ball that was removed in step and nearly out of view as shown.
#22.
�TEP 80 �TEP 81
Slide the high/low shift rail onto the output gear Slide the gear assembly into the center housing.
assembly.

�TEP 82 �TEP 83
Install the front output shift collar onto the shift Tap the output assembly into place using a rubber
fork hammer.

SiEP 84 SiEP 85
Apply the grease to the counter shaft shim face on Apply the new shim provided in the kit. Note the
the center housing. position of the tab in the shim. Make sure the tab
fits into the notch in the housing.
STEP 86 STEP 87
Replace the rubber seal on the counter shaft. The Place the counter shaft gear onto the shim.
rubber seal should rest in the groove cut into the
shaft.

STEP ee STEP 89
Slide the counter shaft through the counter shaft Apply grease to the new counter shaft bearing provided
gear and shim. and slide it into the center of the counter shaft gear.

STEP 90 STEP 91
Slide the bearing spacer into place as shown. Apply the grease to the second new counter shaft
bearing provided and slide it into the center of the
counter shaft gear.
INSTALL INSTRUCTIONS (CONT'D.,)
STEP 92 $TEP 93
Slide the input gear assembly into place. Apply grease in the counter shaft hole in the rear
housing.

SiEP 94 STEP 95
Place the new counter shaft shim over the hole in the Apply Permatex® Ultra Grey® Silicon to both sides of
rear housing. Note the position of the tab on the shim. the gasket and lay the gasket over the rear housing.
Make sure the tab fits into the notch in the housing as
shown.

STEP 96 STEP 97
Slide the rear housing on top of the center housing Tap the center and rear housings together with a
section. Make sure not to pinch or damage the gasket. rubber hammer.
The counter shaft must fit into the center of the shim.
INSTALL INSTRUCTIONS (COMT'D.)
STEP se SYEP 99
Turn the counter shaft with pliers so that the lock Install the eleven (11) bolts that hold the center
tab slot lines up with the tab hole. Install the lock and rear sections together. Note: Be sure to install
tab and bolt. the bolts in the same places they were removed
from. Not all of the bolts are the same size.

STEP 100 STEP 101

Apply Permatex® Ultra Grey® Silicon to both Install the front housing section onto the center
sides of the front housing gasket. Place the gasket housing.
over the front housing.

STEP 102 STEP 103

Install the 7 bolts holding the front housing. Note: Install the front output flange. Install the flange nut
Be sure to install the bolts in the same places as and re-stake the nut into position.
they were removed from. Not all of the bolts are
the same size.
STEP 104 SYEP 105
Install the input flange. Install the flange nut and Install the rear output flange. Note that the rear
re-stake the nut into position. output flange is the tall flange and is different than
the other two flanges. Install the flange nut and
restake the nut into position.

STEP 106 STEP 107

Reinstall the steel ball in the bottom of the case. Install the spring into the bottom of the case.

STEP 108 STEP 109

Install the detent plug into the bottom of the case. Install the speedometer drive unit.
STEP 110 SYEP 111
Install the speedometer drive bolt. Install the 4wd indicator ball (removed in step #3)
as shown.

STEP 11Z SiEP 113

Install the 4wd indicator switch as shown. Place the transfer case back onto the transmission
jack and raise the transfer case into the vehicle.
Secure the transfer case to the chassis using the (3)
nuts removed in Step 7. Using a torque wrench,
torque the nuts to 18.5-25 ft-lbs (25-35 N-m).

STEP 114 STEP 115

Reconnect the 4WD position electrical switch. Reconnect the speedometer drive cable to the
transfer case.
STEP 11$ STEP 117
Reconnect the control lever to the transfer case. Reinstall the clamp and boot back onto the transfer
case.

TRANSFER CASE

STEP 118 STEP 119

Reinstall all (3) drivelines onto the transfer case driveline Reinstall the transfer case drain plug. Remove the fill
flanges using the (12) nuts and bolts removed in Step 1. plug and fill the transfer case with the API GL-5 SAE
Using a torque wrench, torque to nuts and bolts 17-21.5 75W-90 gear oil or the gear oil recommended in your
ft-lbs (23-30 N-m). Suzuki Samurai Owner's Manual. Reinstall the fill plug.
Using a torque wrench, torque both plugs to 13.5-20

STEP 120
Verify all bolts have been reinstalled and torqued. Verify all wiring plugs and cables have been reconnected. Take the
vehicle for a short test drive and verify shift lights and speedometer function. After the transfer case cools, recheck the
gear oil level and top off as necessary. After the first 10 miles of driving, recheck the gear oil level and top off as
necessary.

MAINTENANCE
Change the gear oil after the first 1,000 miles or after the first trail ride, whichever comes first. After the initial oil change,
change the gear oil once a year or every 10,000 miles, whichever comes first. Check the gear oil level every time the
engine oil is changed. Also check the gear oil level whenever the vehicle rolls over, as gear oil may leak out.
REPLACEMENT PARTS

303438-3 (4.16)
303343-3 (4.90)
105012-3 (6.5)

\..303439.3 !
4.16)
303344- 3 4.90)
303440-3 (4.16)
303345-3 (4.90)
105013-3(6.5)
10 5011-3 6.5)
:---- --
-;
-------- - -----------------·---

'
I.

!Df'°'"'
303923-3 (JIMNY 4.16 & 4 90)
(6.5)
•

r1
_
__
1.---___
_
_
_
_
_
......
'l 105014-3